JP2021064255A - Maintenance schedule creation program, maintenance schedule creation method, and maintenance schedule creation device - Google Patents

Abstract

To efficiently create a maintenance schedule for a plant having a plurality of facilities.SOLUTION: A first processing capacity of a process without facility outage is acquired based on first information that defines each step of a process using a plurality of facilities, an interrelationship between the processes, and a processing capacity of each process. A second processing capacity of a process with one of the plurality of facilities stopped is acquired based on the first information. A maintenance cost of a maintenance schedule is calculated based on the first processing capacity and the second processing capacity. A start date constraint for a maintenance task is created for each pair of maintenance tasks that can be performed on overlapping dates based on the second information that defines the conditions for each of a plurality of maintenance tasks. A maintenance schedule is created and the maintenance cost is calculated while switching the validness or invalidness of each of the plurality of constraints.SELECTED DRAWING: Figure 9

Description

The present invention relates to a maintenance schedule creation program, a maintenance schedule creation method, and a maintenance schedule creation device.

In a plant such as a factory or a power plant, long-term and / or periodic maintenance work is performed on each of a plurality of facilities arranged in the plant.

Examples of "equipment" include machines, equipment, piping and the like. "Maintenance work" is, for example, work related to maintenance or maintenance such as inspection, cleaning, repair, replacement, and renewal of equipment. Maintenance work may be referred to as "maintenance".

It is conceivable that the maintenance work manager adjusts the schedule for executing the work for each of the plurality of facilities in advance, creates an annual maintenance schedule, and carries out the maintenance work according to the maintenance schedule.

Japanese Unexamined Patent Publication No. 2010-282353 Japanese Unexamined Patent Publication No. 9-285948

Plants often have many large and small facilities. Since there are a plurality of maintenance works for each equipment to be maintained, the total number of maintenance works for the entire plant and the number of combinations of schedules for each work are enormous.

Therefore, it is difficult for the manager to easily create an optimal schedule (for example, the maintenance cost is minimized) for such a plant.

In one aspect, the present invention aims to efficiently create a maintenance schedule for a plant in which a plurality of facilities are arranged.

In one aspect, the maintenance schedule creation program may cause the computer that creates the maintenance schedule for each of the plurality of facilities to perform the following processes. The processing is based on the first information that defines each step of the process using the plurality of facilities, the interrelationship between the steps, and the processing capacity of each step, and the processing is performed in a state without equipment stoppage. The first processing capacity of the process may be acquired. Further, in the processing, the second processing capacity of the process in the equipment stopped state of any of the plurality of equipments may be acquired based on the first information. Further, in the processing, the maintenance cost of the maintenance schedule may be calculated based on the first processing capacity and the second processing capacity. In addition, the process may create a constraint on the start date of the maintenance work for each pair of maintenance work that can be executed on the overlapping schedule, based on the second information that defines the conditions for each of the plurality of maintenance work. Further, in the process, the maintenance schedule may be created and the maintenance cost may be calculated while switching the validity or invalidity of each of the plurality of constraints.

On one side, maintenance schedules can be efficiently created in plants with multiple facilities.

It is a figure which shows the comparative example of the maintenance schedule creation method. It is a figure which shows the comparative example of the maintenance schedule creation method. It is a figure which shows the calculation example of the opportunity loss cost. It is a figure which shows the example which expressed the processing process of a plant as the network diagram of the product which flows between each process. It is a block diagram which shows the hardware configuration example of the computer which realizes the function of the maintenance schedule creation apparatus which concerns on one Embodiment. It is a block diagram which shows the functional structure example of the maintenance schedule creation apparatus which concerns on one Embodiment. It is a figure which shows an example of the processing process information. It is a figure which shows an example of maintenance schedule information. It is a flowchart which shows the whole operation example which concerns on the creation of maintenance schedule by a creation apparatus. It is a figure which visualized the processing process information as a directed graph which connected the process by the arrow from the previous process to the next process. It is a figure which shows an example of the network diagram of the processing process illustrated in FIG. 7. It is a flowchart which shows the operation example by a network diagram creation part. It is a figure which shows an example of the creation method of the network diagram shown in FIG. It is a figure which shows an example of the creation method of the network diagram shown in FIG. It is a flowchart which shows the operation example by the maximum processing capacity calculation part. It is a figure which shows an example of the calculation method of the maximum processing capacity based on the network diagram shown in FIG. It is a figure which shows an example of the calculation method of the maximum processing capacity based on the network diagram shown in FIG. It is a figure which shows an example of the collection processing by the inter-working constraint creation part. It is a figure which shows an example of the executionability confirmation processing by the work-to-work constraint creation part. It is a figure which shows an example of the inter-working constraint. It is a flowchart which shows an example of the maintenance schedule creation process by a schedule creation part. It is a figure which shows an example of the maintenance schedule creation method. It is a figure which shows an example of the maintenance schedule creation method. It is a figure which shows an example of the maintenance schedule creation method. It is a flowchart which shows an example of the maintenance cost determination process by the maintenance cost determination part. It is a figure which shows an example of the calculation method of the daily processing capacity. It is a figure which shows the display example of the creation result of maintenance schedule and maintenance cost. It is a figure which shows the configuration example of the system which includes a creation apparatus and a terminal.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the embodiments described below are merely examples, and can be variously modified and implemented without departing from the spirit. In the drawings used in the following embodiments, the parts having the same reference numerals represent the same or similar parts unless otherwise specified.

[1] Embodiment [1-1] Creation of maintenance schedule FIGS. 1 and 2 are diagrams showing comparative examples of maintenance schedule creation methods. As shown in FIG. 1, in the comparative example, the manager adjusts the work schedule for each work in the equipment maintenance work 100 and creates the maintenance schedule 200. In schedule adjustment, the administrator considers, for example, restrictions (conditions) regarding the work execution period (deadline), the number of work days, the target equipment, the person in charge of the work, the equipment used for the maintenance work, and the like.

As an example, as shown in FIG. 2, the manager creates a provisional schedule based on a cycle determined for each facility and work, and adjusts the schedule while performing a constraint satisfaction check and a cost evaluation. Then, the manager creates the maintenance schedule 200 by determining the start date of the work that satisfies the restrictions and reduces the maintenance cost.

Restrictions include, for example, that work is executed within a specified execution period, that the person in charge can execute one work at the same time, that there is an upper limit on the number of devices used such as heavy machinery, and the like. ..

The maintenance cost includes, for example, the cost of work that does not depend on the maintenance date such as material cost and labor cost, the cost of work that depends on the maintenance date such as the residual value (book value) of the material, and the opportunity determined by the combination of work. The cost of loss, may be included.

However, as described above, when creating a maintenance schedule for a plant with many large and small facilities, the number of combinations of schedules is enormous, so create a schedule that satisfies the constraints and reduces the maintenance cost. It's difficult to do. For example, even if a skilled manager creates a maintenance schedule based on experience and knowledge, the more work is done, the more difficult and time-consuming it is to create, so the maintenance cost is manually reduced. It is difficult to identify the schedule to minimize.

Further, a method of automatically generating a schedule by an algorithm such as mathematical optimization can be considered, but when this method is applied to the creation of a maintenance schedule based on the opportunity loss cost, there are the following inconveniences.

(A) Since the opportunity loss cost cannot be expressed as a simple mathematical formula or function, it is difficult to properly calculate the opportunity loss cost.

(B) As the number of operations increases, the search range for the combination of operations becomes wider, so that the optimization processing time increases, and only locally optimal results can be obtained.

Therefore, in one embodiment, as an example of a method for efficiently creating a maintenance schedule, a method that enables a schedule with a low maintenance cost to be created in a short time will be described.

[1-2] Description of One Embodiment First, the opportunity loss cost will be described. FIG. 3 is a diagram showing an example of calculating the opportunity loss cost. As illustrated in FIG. 3, the opportunity loss cost simulates the production volume when one or more facilities are shut down based on the model 300 (see the upper left of FIG. 3) showing the normal manufacturing process and production volume. It may be obtained by doing.

In the example of FIG. 3, as one or more facilities, the machine B1 is stopped (see the lower left of FIG. 3), the machine C is stopped (see the upper right of FIG. 3), and the machines B2 and C are stopped. When this is done (see the lower right of FIG. 3), the respective production amounts are calculated. The opportunity loss cost can be calculated based on the production amount (normal time) of this model 300, the production amount when the equipment is stopped, the equipment stop period, and the like. The production amount shown in FIG. 3 indicates the maximum production amount for a predetermined period (for example, 1 day, 1 hour, 1 minute, etc.).

As illustrated in FIG. 3, the opportunity loss cost due to equipment outages depends not only on the processing process and equipment production capacity, but also on the combination of equipments that are shut down at the same time. In order to reduce the opportunity loss cost, it is effective to process multiple maintenance operations with overlapping equipment outages on overlapping schedules.

As described above, the larger the scale of the plant (the number of facilities), the greater the number of combinations of work. Further, in order to calculate the opportunity loss cost, as illustrated in FIG. 2, the method of calculating the cost for each equipment or work and taking the sum is not sufficient, and it takes time and effort.

Therefore, the production apparatus according to one embodiment creates a maintenance schedule by paying attention to the relationship between the processing process of the plant and the products flowing between the processes. Hereinafter, the creating device may be simply referred to as a "creating device".

FIG. 4 is a diagram showing an example in which the processing process of the plant is represented as a network diagram NE of products flowing between the processes. Hereinafter, for convenience, the production apparatus will be described as creating a network diagram NE as an example of information indicating the relationship between the processing process of the plant and the products flowing between the processes, but the present invention is not limited to this.

In one embodiment, the network diagram NE is not essential. For example, the creating device may use or create various information such as a table, a DB (Database), and an array showing the above relationship instead of the network diagram NE. Good.

The network diagram NE is a diagram in which each "process" is arranged as a node ND between the start "s" and the end "e" of the processing process of the plant, and the nodes ND are connected by arrows. Arrows indicate product flow between processes. In the network diagram NE shown in the upper part of FIG. 4, an example of the processing amount that can be processed in each process is shown above the arrow.

A "process" is one process in which a process is subdivided, and may be referred to as a "procedure". In the "process", one or more facilities may be used. Equipment may be used in duplicate between "processes". In the maintenance work, one or more operations may be performed for each "process".

In one embodiment, the creation device may calculate the opportunity loss cost using the network diagram NE, as illustrated on the left side of FIG. In the network diagram NE shown in the middle left of FIG. 4, an example of the maximum flow rate of each process when the product flows from the upstream to the downstream is shown above the arrow. In the lower left of FIG. 4, assuming the case where the maintenance work of the process C1 is carried out, the processing amount of each process when the inflow and outflow processing amount (quantity of products) in the process C1 is set to "0". An example is shown. It can be seen that the processing amount decreases from "20" to "10" from the middle left to the lower left in FIG.

Further, in one embodiment, the creation device may generate a constraint for reducing the opportunity loss cost by using the network diagram NE as illustrated on the right side of FIG. As illustrated in the middle right of FIG. 4, when the process C1 using the equipment “EQ04-1” is stopped, the flow rate of the product in the process D1 using the equipment “EQ05” is also “0”. Therefore, it can be seen that the process D1 is a process in which the work should be performed so that the schedule overlaps with the process C1, in other words, it is effective in reducing the opportunity loss cost. By using such constraints, a good solution can be obtained in a short time in the optimization calculation of the maintenance schedule.

Therefore, as illustrated in the lower right part of FIG. 4, the creation device is optimized by appropriately adding restrictions such that the schedules of a plurality of independently executed works overlap each other, thereby utilizing the characteristics peculiar to the maintenance schedule. Calculations can be carried out.

As described above, the creation device according to the first embodiment has an opportunity loss cost due to a change in the processing amount when the maintenance work is performed, as illustrated on the left side of FIG. 4, based on the relationship shown in the network diagram NE. And evaluate the schedule.

Further, as illustrated on the right side of FIG. 4, the creation device finds a pair of work that should be executed on overlapping schedules, sets it as a constraint in optimization (inter-work constraint), and enables the constraint as appropriate to search for a solution. The space can be limited to the area where a good solution exists. As a result, the amount of calculation can be reduced and the solution quality can be improved.

[1-3] Configuration Example of One Embodiment The creating device may be configured as an information processing device, for example, a computer such as a server or a PC (Personal Computer). The creating device may be, for example, a virtual server (VM) or a physical server. Further, the function of the creating device may be realized by one computer or may be realized by two or more computers.

The creation device may be installed in a plant, a data center, or the like and operated as a so-called on-premises. Further, at least a part of the functions of the creation device may be realized by using HW (Hardware) resources and NW (Network) resources provided in the cloud environment.

[1-3-1] Hardware Configuration Example FIG. 5 is a block diagram showing an HW configuration example of a computer 10 that realizes the function of the creation device. When a plurality of computers are used as the HW resource that realizes the function of the creating device, each computer may have the HW configuration illustrated in FIG.

As shown in FIG. 5, the computer 10 has an HW configuration, for example, a processor 10a, a memory 10b, a storage unit 10c, an IF (Interface) unit 10d, an I / O (Input / Output) unit 10e, and a reading unit. It may be provided with 10f.

The processor 10a is an example of an arithmetic processing unit that performs various controls and operations. The processor 10a may be connected to each block in the computer 10 so as to be able to communicate with each other by the bus 10i. The processor 10a may be a multiprocessor including a plurality of processors, a multicore processor having a plurality of processor cores, or a configuration having a plurality of multicore processors.

Examples of the processor 10a include integrated circuits (ICs) such as CPUs, MPUs, GPUs, APUs, DSPs, ASICs, and FPGAs. A combination of two or more of these integrated circuits may be used as the processor 10a. CPU is an abbreviation for Central Processing Unit, and MPU is an abbreviation for Micro Processing Unit. GPU is an abbreviation for Graphics Processing Unit, and APU is an abbreviation for Accelerated Processing Unit. DSP is an abbreviation for Digital Signal Processor, ASIC is an abbreviation for Application Specific IC, and FPGA is an abbreviation for Field-Programmable Gate Array.

The memory 10b is an example of an HW that stores information such as various data and programs. Examples of the memory 10b include a volatile memory such as a DRAM (Dynamic Random Access Memory).

The storage unit 10c is an example of an HW that stores information such as various data and programs. Examples of the storage unit 10c include a magnetic disk device such as an HDD (Hard Disk Drive), a semiconductor drive device such as an SSD (Solid State Drive), and various storage devices such as a non-volatile memory. Examples of the non-volatile memory include flash memory, SCM (Storage Class Memory), ROM (Read Only Memory) and the like.

Further, the storage unit 10c may store a program 10g (maintenance schedule creation program) that realizes all or a part of various functions of the computer 10. For example, the processor 10a of the creating device can realize the function as the creating device by expanding and executing the program 10g stored in the storage unit 10c in the memory 10b.

The IF unit 10d is an example of a communication IF that controls connection with a network and communication. For example, the IF unit 10d may include an adapter compliant with LAN (Local Area Network) such as Ethernet (registered trademark) or optical communication (for example, FC (Fibre Channel)). The adapter may support one or both wireless and wired communication methods. For example, the program 10g may be downloaded from the network to the computer 10 via the communication IF and stored in the storage unit 10c.

The I / O unit 10e may include one or both of an input device and an output device. Examples of the input device include a keyboard, a mouse, a touch panel, and the like. Examples of the output device include a monitor, a projector, a printer and the like.

The reading unit 10f is an example of a reader that reads data and program information recorded on the recording medium 10h. The reading unit 10f may include a connection terminal or device to which the recording medium 10h can be connected or inserted. Examples of the reading unit 10f include an adapter compliant with USB (Universal Serial Bus) and the like, a drive device for accessing a recording disk, a card reader for accessing a flash memory such as an SD card, and the like. The program 10g may be stored in the recording medium 10h, or the reading unit 10f may read the program 10g from the recording medium 10h and store it in the storage unit 10c.

Examples of the recording medium 10h include a non-temporary computer-readable recording medium such as a magnetic / optical disk or a flash memory. Examples of magnetic / optical disks include flexible discs, CDs (Compact Discs), DVDs (Digital Versatile Discs), Blu-ray discs, HVDs (Holographic Versatile Discs), and the like. Examples of the flash memory include semiconductor memories such as USB memory and SD card.

The HW configuration of the computer 10 described above is an example. Therefore, the increase / decrease of HW (for example, addition or deletion of arbitrary blocks), division, integration in any combination, addition or deletion of buses, etc. in the computer 10 may be performed as appropriate.

[1-3-2] Functional configuration example Next, a functional configuration example of the maintenance schedule creating device (creating device) 1 according to the embodiment will be described with reference to FIG. The creation device 1 creates a maintenance schedule for each of the plurality of facilities. As shown in FIG. 6, the creation device 1 exemplifies the memory unit 11, the network diagram creation unit 12, the maximum processing capacity calculation unit 13, the inter-work constraint creation unit 14, the schedule creation unit 15, and the maintenance cost determination. The unit 16 may be provided. At least a part of the functions of blocks 12 to 16 may be written in the program 10g and realized by the processor 10a expanding the program 10g into the memory 10b and executing it.

The memory unit 11 is an example of a storage unit, and may store various information used by the creating device 1. The memory unit 11 may be realized by, for example, a storage area included in at least one of the memory 10b, the storage unit 10c, and the recording medium 10h of the computer 10.

The memory unit 11 may store the processing process information 11a and the maintenance schedule information 11d shown in FIGS. 7 and 8. At least one of the processing process information 11a and the maintenance schedule information 11d may be existing information used for plant management, and may be acquired (input) in advance by the creation device 1 and stored in the memory unit 11. ..

The processing process information 11a is an example of first information that defines each process of a process using a plurality of facilities, the mutual relationship between the processes, and the processing capacity of each process. For example, the processing process information 11a is information indicating the processing process of the plant that finishes the input material into a product through several steps and the processing capacity of each process. In one step in the processing process, a process (flow) is carried out in which the intermediate product received from the previous step is subjected to a predetermined process in that step and passed to the next step. The processing process is defined for each product.

FIG. 7 is a diagram showing an example of processing process information 11a. As shown in FIG. 7, the processing process information 11a is exemplified by a product ID (Identifier) which is an example of a product identifier, a process ID which is an example of a process identifier, a process name which is a process name, and equipment used. , Processing capacity, and next step ID may be included. In the example of FIG. 7, the processing process information 11a defined for the product with the product ID “ABC00123” is shown.

The equipment used is an example of an identifier of the equipment used in the process. When a plurality of equipments are used in the process, identifiers of the plurality of equipments may be set in the equipments used. A numerical value indicating the processing capacity of the process may be set in the processing capacity. Time units and unit systems of processing capacity are arranged between processes having the same product ID. The next process ID is an example of an identifier of the next process of the process. A plurality of identifiers of the next process may be set in the next process ID, which means that the processes are branched and processed in parallel in the next process.

The maintenance schedule information 11d is an example of the second information that defines the conditions for each of the plurality of maintenance operations, and is information in which various information used for determining the maintenance schedule is set for each maintenance operation.

FIG. 8 is a diagram showing an example of maintenance schedule information 11d. As shown in FIG. 8, the maintenance schedule information 11d exemplifies the work ID, the work content, the target equipment ID, the person in charge ID, the number of work days, the start deadline, the completion deadline, and the maintenance work identifier. The item of scheduled work start date may be included.

As the work content, the target equipment for the maintenance work and the content of the maintenance work may be set. The target equipment ID is an example of an identifier of the equipment that is the target of maintenance work. The target equipment ID may be an ID common to the equipment used in the processing process information 11a (see FIG. 7). The person in charge ID is an example of the identifier of the maintenance worker who carries out the maintenance work. The number of working days is an example of the number of days required from the start to the completion of maintenance work.

The start deadline and the completion deadline are examples of the date on which the maintenance work should be started and the date on which the work should be completed. The start deadline and the completion deadline may be, for example, predetermined deadlines by laws and regulations, or may be preset according to the execution cycle of maintenance work and the past execution timing.

The scheduled work start date is an example of the scheduled start date of maintenance work. A tentative scheduled date (for example, start deadline (+ α) or completion deadline-number of working days (-α)) may be set in advance as the scheduled work start date. In one embodiment, a maintenance schedule is created by updating the scheduled work start date by a process described later.

(Operation example of creation device 1)
First, with reference to FIG. 9, an overall operation example related to the creation of the maintenance schedule by the creation device 1 will be described.

As illustrated in FIG. 9, the creating apparatus 1 creates a network diagram 11b of the product flow from the processing process information 11a (step S1).

Here, when the processing process information 11a shown in FIG. 7 is visualized as a directed graph connecting the processes with arrows from the previous process to the next process, it can be seen that the processing flow as illustrated in FIG. 10 is described. ..

FIG. 10 shows an example in which the processing process information 11a of the product ID “ABC00123” illustrated in FIG. 7 is visualized. As illustrated in FIG. 10, the process PR not designated as the next process ID in FIG. 7 is the first process PR, that is, process A (ID: 1). Further, the process PR in which a plurality of next process IDs are designated in FIG. 7 is a process PR that branches into parallel processing in the next process, that is, process B (ID: 2). Further, the process PRs designated as the next process IDs in FIG. 7 are the merging process PRs, that is, the process E (ID: 7).

FIG. 11 is a diagram showing an example of a network diagram 11b of the processing process of the product ID “ABC00123” illustrated in FIG. 7. The network diagram 11b showing the product flow may be created according to the following rules.

(I) Each process, that is, the node ND, is connected by an arrow pointing to the next process.
(Ii) The start node Ns exists before the first step (first step), and the end node Ne exists after the final step.
(Iii) Each arrow has information on the maximum amount of product flowing between processes. The maximum amount flowing on each side is equivalent to the smaller of the processing capacities of the processes at both ends. However, the maximum amount between the start node Ns and the first process is equal to the processing capacity of the first process, and the maximum amount between the end node Ne and the final process is equal to the processing capacity of the final process.

Returning to the description of FIG. 9, the creating apparatus 1 calculates the processing capacity (maximum processing capacity 11c) (Pmax) when there is no stop equipment using the network diagram 11b (step S2).

The creation device 1 sets the variable j to 1 (step S3). Then, the creating device 1 collects information on the process X in which the maintenance work should be performed so that the schedule overlaps with the process i by using the network diagram 11b in which the processing capacity of the process including the target equipment of the work wj is corrected to 0. (Step S4). i is one of the process IDs set in the processing process information 11a.

Here, the maintenance work W including a plurality of works w1, ..., Wn is referred to as W (w1, ..., Wn). Note that n is an integer of 1 or more, and is the number of operations included in the maintenance work W. Further, j is an integer of 1 or more and n or less. For example, in the maintenance schedule information 11d shown in FIG. 8, assuming that the maintenance work for the target equipment ID: EQ01 is W, the three (n = 3) work IDs: T001 to T003 for the target equipment ID: EQ01 are Each corresponds to w1 to w3.

The creation device 1 sets the variable k to 1 (step S5). Then, the creating apparatus 1 collects the work Y = {y1, ..., ym} related to the equipment used in the process X (step S6). Note that m is an integer of 1 or more and is the number of work Y. Further, k is an integer of 1 or more and m or less.

Based on the maintenance schedule information 11d, the creation device 1 determines whether or not the person in charge of the work wj and the work yk is different and the work wj and the work yk can be carried out on the overlapping schedule (step S7).

If NO in step S7, the process proceeds to step S9. If YES in step S7, the maintenance schedule information 11d collects the condition of the scheduled work start date (inter-work constraint 11e) for carrying out the work wj and the work yk on the overlapping schedule (step S8), and k. Is less than a few meters of work Y (step S9).

If YES in step S9, the creation device 1 adds 1 to k (step S10), and the process proceeds to step S7. If NO in step S9, the creation device 1 determines whether or not j is less than the number of operations n (step S11).

If YES in step S11, the creating device 1 adds 1 to j (step S12), and the process proceeds to step S4. If NO in step S11, the creation device 1 determines the scheduled start date of each work (automatic schedule creation) (step S13), and the process ends.

Next, a configuration example of blocks 12 to 16 for executing the processing of each step described above will be described.

(Explanation of network diagram creation unit 12)
The network diagram creation unit 12 represents a process using a plurality of facilities as a network diagram 11b showing the quantity of products flowing into or out of each process based on the processing process information 11a stored in the memory unit 11. This is an example. Further, the network diagram creation unit 12 may store the created network diagram 11b in the memory unit 11.

Hereinafter, an example of a method for creating the network diagram 11b based on the processing process information 11a by the network diagram creating unit 12 will be described.

FIG. 12 is a flowchart showing an operation example by the network diagram creating unit 12, and FIGS. 13 and 14 are diagrams showing an example of the method of creating the network diagram 11b shown in FIG. The processes illustrated in FIGS. 12 to 14 correspond to the processes in step S1 of FIG.

As illustrated in FIG. 12, the network diagram creation unit 12 adds a start node Ns and an end node Ne (step S21; see procedure A in FIG. 13).

In the processing process information 11a, the network diagram creation unit 12 sets the process without the next process as X (in step B in FIG. 13, sets the process E as X = {E}), adds the node ND of the process X, and adds the node ND of the process X. The added node ND and the end node Ne are connected by an arrow (step S22). Further, the network diagram creating unit 12 sets the maximum flow rate of each connected arrow to a value equal to the processing capacity of the process corresponding to the base of the arrow (“30” in step E in step B in FIG. 13) (step S23). ..

In the processing process information 11a, the network diagram creating unit 12 searches for a process Y having any of the processes X (process E in the procedure C in FIG. 13) as the next process (step S24), and whether or not the process Y exists. (Step S25).

If YES in step S25, the network diagram creation unit 12 adds the node ND of step Y (Y = {D1, D2} in step C of FIG. 13), and the added node ND and the next step (FIG. 13). In step C of the above, the node ND of step E) is connected (step S26).

Further, the network diagram creating unit 12 sets the maximum flow rate of each connected arrow to a value equal to the smaller of the processing capacities of the processes at both ends (step S27). For example, in the procedure C of FIG. 13, the network diagram creating unit 12 sets the maximum flow rate of the arrow of the process D1 → the process E to a value equal to “10” of the process D1, and the maximum of the arrow of the process D2 → the process E. The flow rate is set to a value equal to “15” in step D2.

Then, the network diagram creation unit 12 sets Y in X (X = {D1, D2} in the procedure D of FIG. 13) (step S28), and the process shifts to step S24.

Following the procedure D in FIG. 13, the network diagram creating unit 12 executes the following processing in the loop of steps S24 to S28.

In the procedure E of FIG. 14, the network diagram creating unit 12 searches for a process having any of the steps X = {D1, D2} as the next process, and sets Y = {C1, C2}. Then, the network diagram creation unit 12 adds the node ND of the process Y and connects the added node ND and the next process. Further, the network diagram creating unit 12 sets the maximum flow rate of each connected arrow to a value equal to the smaller of the processing capacities of the processes at both ends. Then, the network diagram creation unit 12 sets X = Y = {C1, C2}.

Further, in the procedure F of FIG. 14, the network diagram creating unit 12 searches for the process Y = {B} having any of the steps X = {C1, C2} in the next process, and executes the same process as the procedure E. To do. Further, in the procedure G of FIG. 14, the network diagram creating unit 12 searches for the process Y = {A} having the process X = {B} as the next process, and executes the same process as the procedure E or F.

Next, in the procedure H of FIG. 14, the network diagram creating unit 12 searches for a step Y having the step X = {A} as the next step, but such a step Y does not exist. That is, it becomes NO in step S25 of FIG.

In this case, the network diagram creation unit 12 connects the start node Ns and the process X (process A in the procedure I of FIG. 14) with an arrow pointing toward the process X (step S29). Then, the network diagram creating unit 12 sets the maximum flow rate of each connected arrow to a value equal to the processing capacity of the process X at the tip of the arrow (“30” in the process A in the procedure I of FIG. 14) (step). S30), the current network diagram 11b is stored in the memory unit 11, and the process ends.

(Explanation of maximum processing capacity calculation unit 13)
The maximum processing capacity calculation unit 13 calculates the maximum flow rate flowing into the end node Ne when the product is flowed from the start node Ns to the end node Ne in the network diagram 11b created by the network diagram creation unit 12. In other words, the maximum processing capacity calculation unit 13 is an example of a first acquisition unit that acquires the first processing capacity of the process without equipment stoppage based on the processing process information 11a.

Further, the maximum processing capacity calculation unit 13 may store the calculated maximum flow rate in the memory unit 11 as the maximum processing capacity 11c (Pmax) of the processing process.

The maximum flow rate flowing through the network diagram 11b can be calculated by, for example, an increasing path algorithm such as the Ford-Fulkerson algorithm.

Hereinafter, an example of the calculation method of the maximum processing capacity 11c by the maximum processing capacity calculation unit 13 will be described.

FIG. 15 is a flowchart showing an operation example by the maximum processing capacity calculation unit 13, and FIGS. 16 and 17 are diagrams showing an example of a calculation method of the maximum processing capacity 11c based on the network FIG. 11b shown in FIG. The processes illustrated in FIGS. 15 to 17 correspond to the processes in step S2 of FIG.

As illustrated in FIG. 15, the maximum processing capacity calculation unit 13 sets the current flow of the network FIG. 11b shown in FIG. 11 to the flow rate of all arrows = 0 (step S31; see procedure A in FIG. 16).

The maximum processing capacity calculation unit 13 creates a network (residual network) in which a reverse arrow with a surplus flow rate with respect to the current flow is described (step S32; see the broken line arrow in step B in FIG. 16).

Next, the maximum processing capacity calculation unit 13 searches for a route from the end node Ne to the start node Ns in the residual network (step S33; see the alternate long and short dash arrow in step C in FIG. 16).

The maximum processing capacity calculation unit 13 determines whether or not a route exists (step S34). If YES in step S34, the maximum processing capacity calculation unit 13 adopts one route from the end node Ne to the start node Ns, and updates the current flow using the route (step S35; procedure of FIG. 16). D), the process proceeds to step S32. In procedure D of FIG. 16, the maximum processing capacity calculation unit 13 shows an example in which “10”, which is the minimum flow rate on the path, is flowed in the direction opposite to that of the residual network.

Following the procedure D in FIG. 16, the maximum processing capacity calculation unit 13 executes the following processing in the loop of steps S32 to S35.

In the procedure E of FIG. 17, the maximum processing capacity calculation unit 13 creates the residual network again and searches for a route (see the alternate long and short dash line) from the end node Ne to the start node Ns. Then, in the procedure F of FIG. 17, the maximum processing capacity calculation unit 13 updates the current flow by flowing the flow rate “10” in the direction opposite to the path of the procedure C of FIG. The maximum processing capacity calculation unit 13 obtained the arrows (for example, start node Ns to process B and process E to end node Ne) for which the flow rate “10” has already been set by searching the procedure E. Add the flow rate "10".

Next, the maximum processing capacity calculation unit 13 creates the residual network again in the procedure G of FIG. 17, but there is no route from the end node Ne to the start node Ns (see the alternate long and short dash line). That is, it becomes NO in step S34 of FIG.

In this case, the current flow is the maximum flow path, and the flow rate entering the end node Ne (“20” in procedure H in FIG. 17) is the maximum flow rate. Therefore, the maximum processing capacity calculation unit 13 determines the maximum flow rate to be the maximum processing capacity 11c (Pmax) of this process (step S36; see procedure H in FIG. 17), stores the maximum processing capacity 11c in the memory unit 11, and stores the maximum processing capacity 11c in the memory unit 11. The process ends.

(Explanation of Inter-Work Constraint Creation Unit 14)
The inter-work constraint creation unit 14 is an example of a constraint creation unit that creates a constraint on the start date of the maintenance work for each pair of maintenance work that can be executed on the overlapping schedule based on the maintenance schedule information 11d.

For example, the inter-work constraint creation unit 14 extracts a combination of two works based on the processing process information 11a, the network diagram 11b, and the maintenance schedule information 11d, and generates the inter-work constraint 11e regarding the work start date between the works. You can do it.

The combination of the two extracted works is determined by the collection process of "process X" and "maintenance work Y" and the execution feasibility confirmation process of "work wj" and "work yk" described below. Good.

(Collection process)
Hereinafter, an example of the collection process by the inter-work constraint creation unit 14 will be described. FIG. 18 is a diagram showing an example of collection processing by the inter-work constraint creation unit 14. The process illustrated in FIG. 18 corresponds to the process of steps S3 to S6, S11, and S12 in FIG.

When the work wj is carried out, the work-to-work constraint creation unit 14 collects the process X that leads to a reduction in the opportunity loss cost if the work is performed on a schedule that overlaps with the work wj. For example, the inter-working constraint creation unit 14 calculates the processing capacity by using the network diagram 11b modified by setting the processing capacity of the process i to 0.

As an example, the inter-work constraint creation unit 14 creates a network diagram 11b when the processing capacity of the process C1 in which the target equipment of the work wj is installed is set to 0 in the procedure A of FIG.

Then, the inter-work constraint creation unit 14 calculates the maximum processing capacity of the network in the procedure B of FIG. 18 by the same method as the calculation of the maximum processing capacity 11c described with reference to FIGS. 15 to 17 (one point). See chain line).

At this time, the process X in which the processing amount becomes 0 is the same as when the equipment is stopped. That is, the process X in which the processing amount becomes 0 means that the opportunity loss cost can be reduced as compared with the case where the process X is performed on another day by performing the work on the schedule overlapping with the process i.

Therefore, the inter-work constraint creation unit 14 collects the work Y = {y1, ... ym} related to the equipment used in the process X with reference to the processing process information 11a and the maintenance schedule information 11d. For example, as shown in procedure C of FIG. 18, the inter-work constraint creation unit 14 collects the process in which the input / output becomes 0 as the process X.

In the example of FIG. 18, when the process C1 using the equipment used: EQ04-1 is stopped, the input / output of the process D1 using the equipment used: EQ05 becomes 0. Therefore, the inter-work constraint creation unit 14 determines that the process D1 is a process X in which the work should be performed so that the schedule overlaps with the process C1, and collects such information.

(Executability confirmation process)
Hereinafter, an example of the execution feasibility confirmation process by the inter-work constraint creation unit 14 will be described. FIG. 19 is a diagram showing an example of execution feasibility confirmation processing by the inter-work constraint creation unit 14, and FIG. 20 is a diagram showing an example of the inter-work constraint 11e. The processes illustrated in FIGS. 19 and 20 correspond to the processes of steps S7 to S10 of FIG.

The inter-work constraint creation unit 14 has different and overlapping schedules for work wj and work yk based on the information of work W collected in the collection process and the information of work Y regarding the equipment used in process X. It is confirmed based on the maintenance schedule information 11d whether or not it can be carried out in.

Then, the inter-work constraint creation unit 14 generates a constraint (inter-work constraint 11e) regarding the scheduled work start date between works if it can be executed on the overlapping schedule.

For example, as shown in FIG. 19, the inter-work constraint creation unit 14 is in charge of the maintenance schedule information 11d shown in FIG. 8 when the work w1 is set to the work ID: T006 and the work y1 is set to the work ID: T008. It is determined whether or not the IDs match. In the example of FIG. 19, since the person in charge IDs are W003 and W004, respectively, the inter-working constraint creation unit 14 determines that the person in charge is different.

Further, as shown in FIG. 19, the inter-work constraint creation unit 14 sets the start dates of the work T006 and T008 to S6 and S8, and sets the number of work days of the work T006 and T008 to d6 and d8, and sets the reference numerals A or B. As shown in, it is determined whether or not the schedules overlap.

In reference numeral A of FIG. 19, the inter-work constraint creation unit 14 may determine that the schedules overlap if the start date of the work wj is between the start date and the completion date of the work yk. Alternatively, in reference numeral B of FIG. 19, the inter-work constraint creation unit 14 may determine that the schedules overlap if the start date of the work yk is between the start date and the completion date of the work wj. Reference numerals A and B are opposite patterns to each other.

As illustrated in FIG. 20, the inter-work constraint creation unit 14 may create the inter-work constraint 11e and store it in the memory unit 11. The inter-work constraint 11e includes a table (matrix) 11e-1 showing the presence or absence of a constraint for each combination of two tasks, and an inter-work constraint 11e-2 created for each combination of two constrained tasks (as an example). S8 ≦ S6 ≦ S8 + d8) may be included.

As described above, in the execution enablement confirmation process, the pair of maintenance work that can be executed on the overlapping schedule can be specified, and in the collection process, the pair of maintenance work whose opportunity loss cost is reduced as compared with the case where the schedule is staggered can be specified. it can. In this way, the inter-work constraint creation unit 14 extracts a plurality of maintenance work pairs that can be executed on overlapping schedules and whose opportunity loss cost is reduced as compared with the case where the schedules are staggered. is there.

In the above-mentioned example, the inter-work constraint creation unit 14 determines the match of the person in charge, but the present invention is not limited to this. For example, in the inter-work constraint creation unit 14, in addition to or instead of the agreement of the person in charge, equipment such as tools and equipment (crane, etc.) used for carrying out the work is at least between the work wj and the work yk. It may be determined whether or not the parts match.

(Explanation of schedule creation unit 15)
The schedule creation unit 15 repeatedly executes schedule creation and evaluation while switching between valid and invalid for each combination of the two works of the inter-work constraint 11e created by the inter-work constraint creation unit 14, and the maintenance cost is reduced. Create a maintenance schedule. The maintenance schedule created by the schedule creation unit 15 may be, for example, updating the "scheduled work start date" of the maintenance schedule information 11d.

In other words, the schedule creation unit 15 is an example of an execution unit that creates a maintenance schedule and calculates a maintenance cost while switching the validity or invalidity of each of the plurality of constraints.

The schedule creation unit 15 repeats changing the current state a little (neighborhood search) in the same manner as the optimization method using metaheuristics such as tabu search and GA (Genetic Algorithm), and repeats the optimum solution (neighborhood search). Search for the optimal work start date).

Hereinafter, an example of the maintenance schedule creation process by the schedule creation unit 15 will be described. FIG. 21 is a flowchart showing an example of the maintenance schedule creation process by the schedule creation unit 15, and FIGS. 22 to 24 are diagrams showing an example of the maintenance schedule creation method. The processes illustrated in FIGS. 21 to 24 correspond to at least a part of the processes in step S13 of FIG.

As illustrated in FIG. 21, the schedule creation unit 15 invalidates all the inter-work constraint 11e (step S41) and creates an initial value of the scheduled start date of all the work. For example, the “scheduled work start date” of the maintenance schedule information 11d. The initial value is set in (step S42).

The schedule creation unit 15 sets the maintenance cost of the current schedule, which is calculated by the maintenance cost determination unit 16 described later, as the best plan (step S43), and sets 0 to the number of iterations I (I is an integer of 1 or more) (I is an integer of 1 or more). Step S44).

The schedule creation unit 15 slightly changes the ratio of the scheduled work start dates (step S45), and determines whether or not the number of constraint violations is larger than that before the change (step S46).

If YES in step S46, the schedule creation unit 15 returns the ratio of the scheduled work start date to the state before the change (step S47), and the process shifts to step S50.

If NO in step S46, the maintenance cost determination unit 16 described later calculates the maintenance cost of the schedule (step S48), and the schedule creation unit 15 determines whether or not the maintenance cost is smaller than that before the change (step). S49).

If NO in step S49, the process proceeds to step S47. On the other hand, if YES in step S49, the schedule creation unit 15 determines whether or not I is smaller than the upper limit M of the number of iterations (step S50).

If YES in step S50, the schedule creation unit 15 adds 1 to I (step S51), and the process shifts to step S45.

The processes of steps S44 to S51 shown in FIG. 21 are neighborhood search processes by the schedule creation unit 15, and may be realized by a known method.

If NO in step S50, the schedule creation unit 15 determines whether or not the maintenance cost of the current plan is smaller than the best plan (step S52).

If NO in step S52, the schedule creation unit 15 invalidates the last added work-to-work constraint 11e (step S53). Then, the schedule creation unit 15 collects invalid work-to-work constraints 11e relating to work that is not executed on a schedule that overlaps with any work in the schedule (step S54).

For example, the schedule creation unit 15 extracts the work (work surrounded by a solid line circle) that is not executed on a schedule that overlaps with any of the work shown in the schedule of procedure A in FIG. Further, the schedule creation unit 15 collects (specifies) the constraint invalidated by the inter-work constraint 11e related to the extracted work (the constraint indicated by the black circle in the table 11e-1 of the procedure B in FIG. 22).

The schedule creation unit 15 validates one or more of the collected constraints (step S55), invalidates the inter-work constraint 11e that contradicts the newly enabled constraint (step S56), and shifts the process to step S44.

For example, as shown in procedure C of FIG. 23, the schedule creation unit 15 selects and activates one of the collected inter-work constraints 11e according to a uniform probability distribution. In the example of procedure C, the schedule creation unit 15 selects and activates the constraint of overlapping the work T010 and T002.

As a result, when the schedule creation unit 15 executes the neighborhood search (local search) again to generate the schedule, for example, as shown in step D of FIG. 23, the opportunity loss cost during the period surrounded by the solid line circle. Can be reduced.

If the inter-working constraint 11e is added too much, an unsatisfactory state may occur. When there is a contradiction between the newly activated inter-work constraint 11e and the already valid inter-work constraint 11e, the schedule creation unit 15 causes a contradiction and is already valid as shown in step S56 of FIG. The inter-work constraint 11e is invalidated.

For example, the schedule creation unit 15 extracts all the work-to-work constraints Y that are related to and already valid for the two works related to the newly activated work-to-work constraint X. Then, the schedule creation unit 15 performs mathematical expression processing on the constraint X and the constraint Y, and determines whether or not the constraint can be satisfied by the mathematical expression processing. If the constraint cannot be satisfied, the schedule creation unit 15 invalidates the constraint Y.

For example, as shown in procedure E of FIG. 24, it is assumed that the following (1) and (2) exist as already effective inter-work constraints, and the following (3) is newly enabled.

(1) S2 ≦ S10 ≦ S2 + d2
(2) S10 ≦ S2 ≦ S10 + d10
(3) S9 ≤ S2 ≤ S9 + d9

In this case, when the constraints related to T2 and T9 are processed by mathematical formulas, S9 ≦ S2 = S10 ≦ S9 + d9, and the worker needs to execute the same work T9 and T10 at the same time, which causes a contradiction in the work-to-work constraint 11e.

Therefore, in the example of the procedure E, the schedule creation unit 15 invalidates the inter-work restrictions (1) and (2).

Returning to the description of FIG. 21, if YES in step S52, the schedule creation unit 15 adopts the current plan as the best plan (step S58) and determines whether or not the determination is completed (step S59). As a condition for whether or not the determination is completed, for example, when the number of times the schedule creation process is executed (the number of determinations in step S59 may be) exceeds a predetermined threshold value, or the amount of change in the maintenance cost becomes equal to or less than a predetermined threshold value. For example.

If NO in step S59, the process proceeds to step S54. On the other hand, if YES in step S59, the process ends.

The process of steps S53 to S56 shown in FIG. 21 is a search space modification process (step S60) specialized for creating a maintenance schedule.

(Explanation of maintenance cost determination unit 16)
The maintenance cost determination unit 16 calculates the maintenance cost of the maintenance schedule based on the first processing capacity (maximum processing capacity 11c) and the second processing capacity of the process when one of the plurality of facilities is stopped. This is an example of a calculation unit to be used.

As shown in FIG. 6, the maintenance cost determination unit 16 may optionally include the functions of the processing capacity calculation unit 16a, the opportunity loss cost calculation unit 16b, and the maintenance cost calculation unit 16c.

The processing capacity calculation unit 16a is an example of a second acquisition unit that acquires the second processing capacity of the process in the equipment stop state of any one of the plurality of equipments based on the processing process information 11a, and is an example of the second acquisition unit when the equipment is stopped. Calculate the processing capacity (second processing capacity).

The opportunity loss cost calculation unit 16b calculates the daily opportunity loss cost based on the difference between the maximum processing capacity and the processing capacity when the equipment is stopped.

The maintenance cost calculation unit 16c calculates the maintenance cost of the created maintenance schedule from the sum of the daily opportunity loss costs.

Hereinafter, an example of the maintenance cost determination (calculation) process by the maintenance cost determination unit 16 will be described. In the following description, all dates of the period indicated in the maintenance schedule are indicated by D = {d1, ... dx} (x is an integer of 1 or more).

FIG. 25 is a flowchart showing an example of the maintenance cost determination process by the maintenance cost determination unit 16, and FIG. 26 is a diagram showing an example of a daily processing capacity calculation method. The processes illustrated in FIGS. 25 and 26 correspond to at least a part of the process of step S13 of FIG. 9, a part of step S43 of FIG. 21, and the process of step S48 of FIG.

As illustrated in FIG. 25, the maintenance cost determination unit 16 sets the variable i to 1 (step S61).

The processing capacity calculation unit 16a modifies the network diagram 11b so as to consider the equipment stop based on the maintenance schedule information 11d, and calculates the processing capacity pi of the date di (step S62).

For example, on the date di, the process including the target equipment for the work to be performed on that day cannot be processed due to the influence of the equipment stop, so the processing capacity of the process is considered to be 0. The work to be carried out on that day is set in the maintenance schedule information 11d.

Therefore, the processing capacity calculation unit 16a corrects the network diagram 11b based on the maintenance schedule information 11d, setting the processing capacity of the process to 0. Then, the processing capacity calculation unit 16a calculates the maximum processing capacity by the same method as the calculation of the maximum processing capacity 11c described with reference to FIGS. 15 to 17 by using the modified network FIG. 11b. The processing capacity calculation unit 16a sets the calculated maximum processing capacity as the processing capacity pi of the process on the date di.

For example, as shown in FIG. 26, it is assumed that the date di = 2019/3/11 (one work of the work (T006) related to the target equipment ID: EQ04-1 is scheduled).

When the processing capacity of the process using the equipment EQ04-1 is set to 0 as shown in the upper left of FIG. 26 and the processing capacity of the process C1 is set to 0 as shown in the lower left of FIG. The network diagram 11b of the above is created.

Further, as shown in the upper right of FIG. 26, the processing capacity calculation unit 16a calculates the maximum processing capacity of the network FIG. 11b by the same method as the calculation of the maximum processing capacity 11c described with reference to FIGS. 15 to 17. To do. Then, as shown in the lower right of FIG. 26, the processing capacity calculation unit 16a sets the maximum processing capacity as the processing capacity pi of the process of the date di.

Returning to the description of FIG. 25, the opportunity loss cost calculation unit 16b calculates the reduction rate ri of the processing capacity of the date di based on pi and Pmax (maximum processing capacity 11c) (step S63).

Here, the profit equivalent to the product for which the product could not be manufactured due to the decrease in the plant processing capacity due to the equipment stop is taken as the opportunity loss cost.

The reduction rate ri of the processing capacity of the plant on the date di may be calculated by the following equation (1). In the following equation (1), Pmax is the maximum processing capacity 11c, and pi indicates the processing capacity on the date di.

The opportunity loss cost calculation unit 16b calculates the opportunity loss cost ci on the date di by using the reduction rate ri (step S64).

For example, the opportunity loss cost calculation unit 16b may calculate the opportunity loss cost ci on the date di by the following equation (2). In the following equation (2), N is the maximum daily production amount [pieces / day], and g is the profit [yen] per product. The maximum production amount N and the profit g may be stored in advance in the memory unit 11 as the maximum production amount 11f and the profit 11g, respectively.

ci = riNg (2)

The opportunity loss cost calculation unit 16b can obtain the _daily opportunity loss cost {c1, ..., cNday} during the period by repeating the process shown in FIG. 25 for all the dates of the maintenance schedule period. .. Nday indicates the number of days within the maintenance schedule period.

Returning to the description of FIG. 25, the maintenance cost calculation unit 16c determines whether or not i is smaller than x (step S65). If YES in step S65, the maintenance cost calculation unit 16c adds 1 to i (step S66), and the process shifts to step S62.

If NO in step S65, the maintenance cost calculation unit 16c calculates the maintenance cost C for the entire period indicated in the schedule (step S67), and the process ends.

For example, the maintenance cost calculation unit 16c calculates the maintenance cost _total during the maintenance schedule period. Maintenance costs _{C total,} as shown in the following equation (3) may be the sum of the total cost _{C task} according to the lost opportunity cost _{C loss} and maintenance work in the maintenance period.

C _total = C _loss + C _task (3)

The opportunity loss cost _Cross is calculated by the following equation (4) as the sum of the daily opportunity loss costs ci.

Further, the total cost C _{task for} the maintenance work is calculated by the following equation (5) as the total of the costs c _{task and j for the work j.}

Here, the memory unit 11 may store the maintenance work cost information 11i. The following information shall be retained in the maintenance work cost information 11i.

-Cost of performing work j (constant independent of maintenance implementation date): c _{1, j}
-A function that takes the maintenance date di of work j and the implementation deadline Dj as arguments, which is used to calculate _{the costs c 1, j} that change depending on the maintenance implementation date in relation to _{the work j: f 2, j} ( di, Dj)
-When considering only the residual value of the member as the costs c _{2 and j} , if the residual value becomes 0 yen at the maintenance deadline, the function information shown by the following equation (6) is retained in the maintenance work cost information 11i. ..

f _{2, j} (di, Dj) = a (Dj-di) (6)

Further, the costs c _{task, j} required for each work may be calculated as the sum of the two costs c _{1, j} , c _{2, j.} That is, it may be calculated by the following equation (7).

c _{task, j} = c _{1, j} + c _{2, j} = c _{1, j} + f _{2, j} (di, Dj) (7)

By the above method, the maintenance cost calculation unit 16c calculates the total cost C _task for the maintenance work.

The maintenance cost determination unit 16 may store each calculated cost, for example, maintenance cost _Total , opportunity loss cost _Clos , total cost _Task, etc. in the memory unit 11 as a cost 11h.

As described above, according to the creation device 1 according to the embodiment, it is possible to automatically create a maintenance schedule with a small maintenance cost including the opportunity loss cost in a short time.

In addition, it is possible to formulate a schedule with low maintenance costs.

Furthermore, by adding a constraint for reducing the opportunity loss cost, the solution search is performed only in the area where a good solution exists, so that the number of combinations to be tried can be reduced. Therefore, the amount of calculation can be reduced and a good solution can be obtained in a short time. That is, the schedule creation time can be shortened.

[1-4] Application Example FIG. 27 is a diagram showing a display example of a maintenance schedule and a maintenance cost creation result. As shown in FIG. 27, at least one or more of the following items may be displayed on the display screen 20.

-A maintenance schedule in which the maintenance schedule information 11d is visualized on a Gantt chart (see reference numeral A).
_-Maintenance cost [yen] (see symbol B), which is a bar graph visualization of the daily opportunity loss cost {c1, ..., cNday} during the schedule period.
・ Schedule period.
・ Calculation result of maintenance cost [yen] for the whole period.

FIG. 28 is a diagram showing a configuration example of a system 30 including a creating device 1 and a terminal 40. As shown in FIG. 28, the creator of the maintenance schedule operates the terminal 40 to input the processing process information 11a and the maintenance schedule information 11d into the creation device 1. The schedule creation unit 15 of the creation device 1 outputs the maintenance schedule information 11d (minimum maintenance cost) by the method described above, and transmits it to the terminal 40. At this time, the schedule creation unit 15 may transmit information (HTML file, graph data, etc.) for displaying the display screen 20 shown in FIG. 27 on the monitor or the like of the terminal 40 to the terminal 40.

In this way, the schedule creation unit 15 may specify the maintenance schedule that minimizes the maintenance cost, and output the information of the specified maintenance schedule.

The creation device 1 may be connected to another device such as the terminal 40 so as to be able to communicate with each other via a network. The network may include a WAN (Wide Area Network), a LAN, or a combination thereof. The WAN may include the Internet.

As a result, the creator of the maintenance schedule can easily acquire the schedule with low maintenance cost in a short time only by inputting the processing process information 11a and the maintenance schedule information 11d into the creation device 1. Further, since the obtained schedule is visualized together with the evaluation result by the creating device 1, the operator can easily grasp an appropriate maintenance schedule.

[2] Others The technology according to the above-described embodiment can be modified or modified as follows.

For example, the functional blocks shown in FIG. 6 may be merged or divided in any combination.

[3] Additional Notes The following additional notes will be further disclosed with respect to the above embodiments.

(Appendix 1)
On a computer that creates a maintenance schedule for each of multiple facilities
Based on the first information that defines each step of the process using the plurality of facilities, the interrelationship between the steps, and the processing capacity of each step, the first step of the process without equipment stoppage. Acquire processing power,
Based on the first information, the second processing capacity of the process in the stopped state of any one of the plurality of facilities is acquired.
Based on the first processing capacity and the second processing capacity, the maintenance cost of the maintenance schedule is calculated.
Based on the second information that defines the conditions for each of multiple maintenance tasks, constraints on the start date of maintenance tasks are created for each pair of maintenance tasks that can be performed on overlapping dates.
The maintenance schedule is created and the maintenance cost is calculated while switching the validity or invalidity of each of the plurality of constraints.
A maintenance schedule creation program that executes processing.

(Appendix 2)
The calculation of the maintenance cost is
Based on the difference between the first processing capacity and the second processing capacity, the daily opportunity loss cost of the process is calculated.
The maintenance cost is calculated based on the sum of the daily opportunity loss costs.
The maintenance schedule creation program described in Appendix 1.

(Appendix 3)
The creation of the constraint
Extract multiple pairs of maintenance work that can be performed on overlapping schedules, and the opportunity loss cost is reduced compared to the case where the schedules are staggered.
Generate a constraint on the start date of maintenance work for each extracted pair.
The maintenance schedule creation program described in Appendix 2.

(Appendix 4)
On the computer
Based on the first information, the process is represented as a network diagram showing the quantity of products flowing into or out of each process.
Acquire the first processing capacity and the second processing capacity based on the network diagram.
The maintenance schedule creation program according to any one of Items 1 to 3 for executing the process.

(Appendix 5)
On the computer
When the quantity of products flowing in or out is set to 0 in any of the first steps in the network diagram, there is a second step in which the quantity of products flowing in or out is 0, and the first step is described above. When the first maintenance work for the process and the second maintenance work for the second process can be performed on an overlapping schedule, the constraint is created for the pair of the first and second maintenance work.
The maintenance schedule creation program according to Appendix 4, which executes the process.

(Appendix 6)
On the computer
Identify the maintenance schedule that minimizes the maintenance cost
Output the specified maintenance schedule information,
The maintenance schedule creation program according to any one of Appendix 1 to 5, which executes the process.

(Appendix 7)
A computer that creates a maintenance schedule for each of multiple facilities
Based on the first information that defines each step of the process using the plurality of facilities, the interrelationship between the steps, and the processing capacity of each step, the first step of the process without equipment stoppage. Acquire processing power,
Based on the first information, the second processing capacity of the process in the stopped state of any one of the plurality of facilities is acquired.
Based on the first processing capacity and the second processing capacity, the maintenance cost of the maintenance schedule is calculated.
Based on the second information that defines the conditions for each of multiple maintenance tasks, constraints on the start date of maintenance tasks are created for each pair of maintenance tasks that can be performed on overlapping dates.
The maintenance schedule is created and the maintenance cost is calculated while switching the validity or invalidity of each of the plurality of constraints.
How to create a maintenance schedule.

(Appendix 8)
The calculation of the maintenance cost is
Based on the difference between the first processing capacity and the second processing capacity, the daily opportunity loss cost of the process is calculated.
The maintenance cost is calculated based on the sum of the daily opportunity loss costs.
The maintenance schedule creation method described in Appendix 7.

(Appendix 9)
The creation of the constraint
Extract multiple pairs of maintenance work that can be performed on overlapping schedules, and the opportunity loss cost is reduced compared to the case where the schedules are staggered.
Generate a constraint on the start date of maintenance work for each extracted pair.
The maintenance schedule creation method described in Appendix 8.

(Appendix 10)
The computer
Based on the first information, the process is represented as a network diagram showing the quantity of products flowing into or out of each process.
Acquire the first processing capacity and the second processing capacity based on the network diagram.
The maintenance schedule creation method according to any one of Appendix 7 to 9.

(Appendix 11)
The computer
When the quantity of products flowing in or out is set to 0 in any of the first steps in the network diagram, there is a second step in which the quantity of products flowing in or out is 0, and the first step is described above. When the first maintenance work for the process and the second maintenance work for the second process can be performed on an overlapping schedule, the constraint is created for the pair of the first and second maintenance work.
The maintenance schedule creation method according to Appendix 10.

(Appendix 12)
The computer
Identify the maintenance schedule that minimizes the maintenance cost
Output the specified maintenance schedule information,
The maintenance schedule creation method according to any one of Appendix 7 to 11.

(Appendix 13)
A maintenance schedule creation device that creates maintenance schedules for each of multiple facilities.
The first information that defines each process of the process using the plurality of facilities, the interrelationship between the processes, and the processing capacity of each process, and the second that defines the conditions of each of the plurality of maintenance operations. A storage unit that stores information and
Based on the first information, the first acquisition unit that acquires the first processing capacity of the process without equipment stoppage, and
Based on the first information, a second acquisition unit that acquires the second processing capacity of the process when any of the plurality of facilities is stopped, and
A calculation unit that calculates the maintenance cost of the maintenance schedule based on the first processing capacity and the second processing capacity.
Based on the second information that defines the conditions for each of multiple maintenance tasks, a constraint creation unit that creates constraints on the start date of maintenance tasks for each pair of maintenance tasks that can be executed on overlapping dates.
An execution unit that creates the maintenance schedule and calculates the maintenance cost while switching the validity or invalidity of each of the plurality of constraints.
A maintenance schedule creation device.

(Appendix 14)
The calculation unit
Based on the difference between the first processing capacity and the second processing capacity, the daily opportunity loss cost of the process is calculated.
The maintenance cost is calculated based on the sum of the daily opportunity loss costs.
The maintenance schedule creation device according to Appendix 13.

(Appendix 15)
The constraint creation unit
Extract multiple pairs of maintenance work that can be performed on overlapping schedules, and the opportunity loss cost is reduced compared to the case where the schedules are staggered.
Generate a constraint on the start date of maintenance work for each extracted pair.
The maintenance schedule creation device according to Appendix 14.

(Appendix 16)
Based on the first information, a creation unit for expressing the process as a network diagram showing the quantity of products flowing into or out of each process is provided.
The first acquisition unit and the second acquisition unit acquire the first processing capacity and the second processing capacity, respectively, based on the network diagram.
The maintenance schedule creation device according to any one of Appendix 13 to 15.

(Appendix 17)
The constraint creation unit
When the quantity of products flowing in or out is set to 0 in any of the first steps in the network diagram, there is a second step in which the quantity of products flowing in or out is 0, and the first step is described above. When the first maintenance work for the process and the second maintenance work for the second process can be performed on an overlapping schedule, the constraint is created for the pair of the first and second maintenance work.
The maintenance schedule creation device according to Appendix 16.

(Appendix 18)
The execution unit
Identify the maintenance schedule that minimizes the maintenance cost
Output the specified maintenance schedule information,
Create the maintenance schedule described in any one of Appendix 13 to 17.

1 Maintenance schedule creation device 10 Computer 11 Memory unit 11a Processing process information 11b Network diagram 11c Maximum processing capacity 11d Maintenance schedule information 11e Inter-work constraint 11f Maximum production 11g Profit 11h Cost 11i Maintenance work cost information 12 Network diagram creation unit 13 Maximum processing Capacity calculation unit 14 Work-to-work constraint creation unit 15 Schedule creation unit 16 Maintenance cost determination unit 16a Processing capacity calculation unit 16b Opportunity loss cost calculation unit 16c Maintenance cost calculation unit 20 Display screen 30 System 40 Terminal

Claims (8)

On a computer that creates a maintenance schedule for each of multiple facilities
Based on the first information that defines each step of the process using the plurality of facilities, the interrelationship between the steps, and the processing capacity of each step, the first step of the process without equipment stoppage. Acquire processing power,
Based on the first information, the second processing capacity of the process in the stopped state of any one of the plurality of facilities is acquired.
Based on the first processing capacity and the second processing capacity, the maintenance cost of the maintenance schedule is calculated.
Based on the second information that defines the conditions for each of multiple maintenance tasks, constraints on the start date of maintenance tasks are created for each pair of maintenance tasks that can be performed on overlapping dates.
The maintenance schedule is created and the maintenance cost is calculated while switching the validity or invalidity of each of the plurality of constraints.
A maintenance schedule creation program that executes processing. The calculation of the maintenance cost is
Based on the difference between the first processing capacity and the second processing capacity, the daily opportunity loss cost of the process is calculated.
The maintenance cost is calculated based on the sum of the daily opportunity loss costs.
The maintenance schedule creation program according to claim 1. The creation of the constraint
Extract multiple pairs of maintenance work that can be performed on overlapping schedules, and the opportunity loss cost is reduced compared to the case where the schedules are staggered.
Generate a constraint on the start date of maintenance work for each extracted pair.
The maintenance schedule creation program according to claim 2. On the computer
Based on the first information, the process is represented as a network diagram showing the quantity of products flowing into or out of each process.
Acquire the first processing capacity and the second processing capacity based on the network diagram.
The maintenance schedule creation program according to any one of claims 1 to 3, which executes the process. On the computer
When the quantity of products flowing in or out is set to 0 in any of the first steps in the network diagram, there is a second step in which the quantity of products flowing in or out is 0, and the first step is described above. When the first maintenance work for the process and the second maintenance work for the second process can be performed on an overlapping schedule, the constraint is created for the pair of the first and second maintenance work.
The maintenance schedule creation program according to claim 4, wherein the process is executed. On the computer
Identify the maintenance schedule that minimizes the maintenance cost
Output the specified maintenance schedule information,
The maintenance schedule creation program according to any one of claims 1 to 5, which executes the process. A computer that creates a maintenance schedule for each of multiple facilities
Based on the first information that defines each step of the process using the plurality of facilities, the interrelationship between the steps, and the processing capacity of each step, the first step of the process without equipment stoppage. Acquire processing power,
Based on the first information, the second processing capacity of the process in the stopped state of any one of the plurality of facilities is acquired.
Based on the first processing capacity and the second processing capacity, the maintenance cost of the maintenance schedule is calculated.
Based on the second information that defines the conditions for each of multiple maintenance tasks, constraints on the start date of maintenance tasks are created for each pair of maintenance tasks that can be performed on overlapping dates.
The maintenance schedule is created and the maintenance cost is calculated while switching the validity or invalidity of each of the plurality of constraints.
How to create a maintenance schedule. A maintenance schedule creation device that creates maintenance schedules for each of multiple facilities.
The first information that defines each process of the process using the plurality of facilities, the interrelationship between the processes, and the processing capacity of each process, and the second that defines the conditions of each of the plurality of maintenance operations. A storage unit that stores information and
Based on the first information, the first acquisition unit that acquires the first processing capacity of the process without equipment stoppage, and
Based on the first information, a second acquisition unit that acquires the second processing capacity of the process when any of the plurality of facilities is stopped, and
A calculation unit that calculates the maintenance cost of the maintenance schedule based on the first processing capacity and the second processing capacity.
Based on the second information that defines the conditions for each of multiple maintenance tasks, a constraint creation unit that creates constraints on the start date of maintenance tasks for each pair of maintenance tasks that can be executed on overlapping dates.
An execution unit that creates the maintenance schedule and calculates the maintenance cost while switching the validity or invalidity of each of the plurality of constraints.
A maintenance schedule creation device.

Images