JP2021197026A - Operation loss analysis system and operation loss analysis method - Google Patents

Abstract

To provide an operation loss analysis system that can make an evaluation including the influence of equipment stop on other works, and an operation loss analysis method.SOLUTION: An operation loss analysis system has: a steady time calculation unit by which a steady work time in which operation stop of equipment does not delay an operation of the equipment or a work of a worker is calculated for each operation status on the basis of operation status information indicating an operation status including an operating state of the equipment or a working state of the worker and operation result information in which an operation result of the equipment or a work result of the worker for manufacturing a product or a component is recorded for each operation status; and an operation loss calculation unit by which an excess of the steady work time for each operation status is calculated as an operation loss on the basis of the steady work time calculated for each operation status and the operation result information.SELECTED DRAWING: Figure 1

Description

The present invention relates to a technique for analyzing an operating loss at a manufacturing site in a factory that produces a product.

As a background technique, there is Patent Document 1. In this gazette, "operation data includes event data representing an event that occurs in a machine and state data representing the state of the machine, and the inference unit describes event data about past, present, and future events at any time. Infer the reason for non-operation based on the inference data including the data on whether or not the machine has occurred and the inference data including the data on the past, present, and future of the state data at any time. . "."

Japanese Unexamined Patent Publication No. 2019-95879

Social infrastructure system products such as control panels are produced in high-mix low-volume production, and the processing equipment and parts required for each product differ. For this reason, compared to mass-produced products, there is an operational loss such as a longer stagnation time in preparation time such as setup and actual processing time depending on the manufacturing order, worker skills, equipment and parts troubles, etc. appear. Since the work repeatability of these products is low, it is difficult to identify the cause of operational loss, and the examination of improvement measures was largely based on the experience of experts and individual case studies. Therefore, it is important to identify the factors that cause these operational losses that reduce the productivity of the manufacturing site and the degree of their impact at an early stage, and to formulate countermeasures.

On the other hand, Patent Document 1 describes a method of inferring the reason for non-operation from the event occurrence log of the equipment and registering the reason in association with the non-operation time. However, these methods are factor analysis for the non-operating time itself such as the alarm stop that occurred in the equipment, and the influence (operation loss) such as the increase in time for recovery preparation and setup in the post-work due to these alarm stops. ) Cannot be measured.

Therefore, an object of the present invention is to provide an operation loss analysis system and an operation loss analysis method that can evaluate the influence of operation loss on other work due to equipment stoppage.

In order to solve the above problems, the operation loss analysis system according to the present invention manufactures operation status information indicating an operation status including an operation state of equipment or a work state of an operator, and a product or a part for each operation status. There is no effect on the operation of the equipment or the work of the worker being stagnant due to the shutdown of the equipment based on the operation record of the equipment or the operation record information in which the work record of the worker is recorded. Excess of the steady work time for each operation status based on the steady time calculation unit that calculates the steady work time for each operation status, the steady work time calculated for each operation status, and the operation record information. It is configured as an operating loss analysis system characterized by having an operating loss calculation unit that calculates minutes as an operating loss.

According to the present invention, it is possible to evaluate the influence of the operation loss caused by the shutdown of the equipment on other work.

It is a figure which shows an example of the processing flow in this Example. It is a block diagram which shows the whole system configuration which concerns on this Example. It is a figure which shows an example of the equipment processing product information. It is a figure which shows an example of the operation record information. It is a figure which shows an example of the operation status information. It is a figure which shows an example of the operation loss analysis history information. It is a figure which shows an example of the operating time total information. It is a figure which shows an example of the operation loss influence degree information. It is a figure which shows an example of the operation loss detailed information. It is a figure which shows an example of the input screen in this Example. It is a figure which shows an example of the detailed processing flow of the processing step S120 in this Example. It is a figure which shows an example of the transition of the abnormality determination flag generated and cleared in the processing step S1203 or S1206 in this Example. It is a figure which shows an example of the abnormality determination list generated in the process step S1205 in this Example. It is a figure which shows an example of the steady working time by operation status calculated in the processing step S130 in this Example. It is a figure which shows an example of the permissible time for each operation status calculated in the processing step S130 in this Example. It is a figure which shows an example of the calculation result of the operation loss calculated in the processing step S140 in this Example. It is a figure which shows an example of the output screen in this Example.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The following description and drawings are examples for explaining the present invention, and are appropriately omitted and simplified for the sake of clarification of the description. The present invention can also be implemented in various other forms. Unless otherwise specified, each component may be singular or plural.

The positions, sizes, shapes, ranges, etc. of each component shown in the drawings may not represent the actual positions, sizes, shapes, ranges, etc., in order to facilitate understanding of the invention. Therefore, the present invention is not necessarily limited to the position, size, shape, range and the like disclosed in the drawings.

In the following description, various information may be described by expressions such as "table" and "list", but various information may be expressed by a data structure other than these. The "XX table", "XX list", etc. may be referred to as "XX information" to indicate that they do not depend on the data structure. When expressions such as "identification information", "identifier", "name", "ID", and "number" are used in explaining the identification information, these can be replaced with each other.

When there are a plurality of components having the same or similar functions, they may be described by adding different subscripts to the same reference numerals. However, if it is not necessary to distinguish between these multiple components, the subscripts may be omitted for explanation.

Further, in the following description, a process performed by executing a program may be described, but the program is determined by being executed by a processor (for example, a CPU (Central Processing Unit) or a GPU (Graphics Processing Unit)). Since the processed processing is appropriately performed using a storage resource (for example, a memory) and / or an interface device (for example, a communication port), the main body of the processing may be a processor. Similarly, the main body of the process of executing the program may be a controller, an apparatus, a system, a computer, or a node having a processor. The main body of the processing performed by executing the program may be any arithmetic unit, and may include a dedicated circuit (for example, FPGA (Field-Programmable Gate Array) or ASIC (Application Specific Integrated Circuit)) for performing specific processing. ..

The program may be installed from the program source into a device such as a calculator. The program source may be, for example, a program distribution server or a computer-readable storage medium. When the program source is a program distribution server, the program distribution server includes a processor and a storage resource for storing the program to be distributed, and the processor of the program distribution server may distribute the program to be distributed to other computers. Further, in the following description, two or more programs may be realized as one program, or one program may be realized as two or more programs.

The case where the operation loss analysis system and the operation loss analysis method according to the present embodiment are applied to the manufacturing site of a factory that produces products and parts will be described in detail below, but the present invention is not limited to this example. , Others It can be applied to various sites where various products such as equipment and devices are manufactured.

FIG. 1 shows an example of a processing flow in this embodiment, and FIG. 2 is a functional block diagram showing a system configuration of this embodiment.

In FIG. 2, the operation loss analysis system 10 is a device including a PC such as a server or a terminal and software mounted on the PC, and includes an input / output unit 100, a storage unit 200, and a calculation unit 300. There is.

The input / output unit 100 is for acquiring data necessary for the processing of the arithmetic unit 300 and displaying the processing result. For example, an input device such as a keyboard or a mouse, a communication device for communicating with the outside, or a disk-type storage medium. It is configured to have a recording / playback device, an output device such as a CRT or an LCD monitor, and the like.

The storage unit 200 stores input information 210 used in the processing of the calculation unit 300 and output information 220 for storing the processing result, and is composed of a storage device such as a hard disk drive or a memory.

The input information 210 includes equipment processed product information 211, operation record information 212, and operation status information 213, and these information will be described below.

The equipment processed product information 211 is information for managing a product processed by equipment at a manufacturing site, and includes, for example, processing ID, equipment, product ID, product type, and processing date information, as shown in FIG. In the production record information 211 of FIG. 3, for example, in the actual result of processing ID "100", the product ID "P100" whose product type is "A" in the equipment "M01" was processed on the processing date "2019/10/1". It is shown that.

The operation record information 212 is information for managing the operation status and the operation time at the time of processing with respect to the equipment processing product information 211. For example, as shown in FIG. 4, the operation record ID, the processing ID, the operation status, and the operation record information 212 are used. Includes alarm ID, start time, end time, and elapsed time information. In the operation record information 212 of FIG. 4, for example, in the actual results of the actual ID "1000" and the machining ID "100", the operation status ID is "W01" at the beginning, and the operation starts at "09:00" to "09: It ends at "09", indicating that the elapsed time was "9 (minutes)". Further, the alarm ID is information for specifying the type of alarm recorded when the operation status ID becomes the alarm stop (“W04” in this embodiment). The type of alarm indicates an event that may cause a problem in processing a target product, such as a processing defect, a tool change, a line abnormality, or an equipment defect. Here, the details of the operation status will be described later.

The operation status information 213 is information for managing the operation status that can be acquired as an operation log for various facilities at the manufacturing site. For example, as shown in FIG. 5, the operation status ID, the operation status name, and the operation loss calculation. Contains flag information. As illustrated below, the operation status information 213 includes the operating status of the equipment for processing products and parts (or peripheral devices thereof), the operation of the equipment, and the like, and the operator prepares for the above processing. Includes the work status of the worker such as (or post-processing).

In the operation status information 213 of FIG. 5, in this embodiment, it is shown that four operation states of the operation status “condition setting”, “setup”, “machining”, and “alarm stop” can be recorded as an operation log. The "condition setting" indicates a state in which the processing conditions for processing the equipment are input from a monitor or the like provided as a peripheral device of the equipment. "Setup" indicates a state in which jigs and tools required for processing with equipment are being installed and adjusted. "Processing" refers to the state in which the equipment is actually processing the product. "Alarm stop" indicates a state in which the equipment is stopped due to various malfunctions or abnormalities. In addition, the operation loss calculation flag "0 to 2" is assigned to each of these operation statuses. The operation loss calculation method using this flag will be described later. In the following, the operation status is explained using "condition setting", "setup", "machining", and "alarm stop", but these are just examples, and the operating status and work of various other equipment. The work status of the person may be included in the operation status information.

Further, the output information 220 includes the operation loss analysis history information 221, the operation time total information 222, the operation loss influence degree information 223, and the operation loss detailed information 224, and each information will be described below.

The operation loss analysis history information 221 is information for managing the history of using the operation loss analysis system 10. For example, as shown in FIG. 6, the analysis ID, the start period, the end period, the condition (equipment), and the condition. Includes information on (variety), conditions (processing date), steady-state time allowance (%), and analysis date and time. In the operation loss analysis history information 221 of FIG. 6, in the history of the analysis ID "100", the system is used on the analysis date and time "2019/11/1", and the period of the operation record information 212 to be analyzed is "2019". From "10/1" to "2019/10/31", equipment, product type, and processing date are not specified as conditions for analysis / aggregation unit of operating loss (flag "0" is set for each), and routine work is performed. It shows that the permissible value as time is up to "10 (%)". The method of inputting and analyzing this information will be described later. In the steady working time, as in the case of the operation status information 213, the operating time of the equipment for processing the product or part (or its peripheral device) in the steady state, the operation of the equipment, etc. Includes the worker's working time in steady state, such as preparation (or post-processing) for the above processing.

The operating time total information 222 is information for managing the operating time for each equipment in the analysis target period specified in the operating loss analysis history information 221. For example, as shown in FIG. 7, the analysis ID, the equipment, and the operation Contains time (h) information. In the operating time aggregated information 222 of FIG. 7, it is shown that the operating time of the equipment “M01” was “180 (h)” in the period indicated by the analysis ID “100”.

The operation loss impact information 223 manages the result of evaluating the influence of the equipment alarm generated during the analysis target period on the work by the worker, the stagnation of equipment processing, the prolongation of the work, etc. (hereinafter referred to as operation loss). For example, as shown in FIG. 8, the information includes analysis ID, alarm ID, operation status ID, operation status name, and loss time (h). In the operation loss impact information 223 of FIG. 8, during the period indicated by the analysis ID “100”, “2 (h)” is applied to each of the operation status IDs “W01” to “W04” due to the occurrence of the alarm ID “A01”. , "3 (h)", "5 (h)", "15 (h)". The method of calculating these loss times will be described later.

The operation loss detailed information 224 is information for managing the detailed information for generating the operation loss influence degree information 223. For example, as shown in FIG. 9, the analysis ID, the alarm ID, the operation status ID, the product type, the equipment, and the operation loss detailed information 224 are used. Includes processing date and loss time (minutes) information. In the operation loss detailed information 224 of FIG. 9, during the period indicated by the analysis ID "100", the alarm ID "A01" is generated in the processing date "2019/10/1", the product type "A", and the equipment "M01". Therefore, the operation loss given to each of the operation status IDs "W01" to "W04" shall be "4 (minutes)", "3 (minutes)", "7 (minutes)", and "30 (minutes)". Is shown.

The calculation unit 300 is for acquiring data necessary for calculation from the input information 210 of the input / output unit 100 and the storage unit 200, and outputting the processing result to the output information 220 of the storage unit 200. The arithmetic unit 300 is composed of an arithmetic processing unit 320 that actually performs arithmetic processing and a memory unit 310 that is a work area for arithmetic processing in the arithmetic processing unit 320.

The memory unit 310 is for temporarily holding the data acquired from the input information 210 of the input / output unit 100 and the storage unit 200, or the result processed by the arithmetic processing unit 320.

The arithmetic processing unit 320 acquires information necessary for processing of the arithmetic processing unit 320 from the input information 210 based on the information such as the analysis period and the analysis method input by the user from the input / output unit 100, and causes the memory unit 310. From the data acquisition unit 321 to be stored, the equipment processing product information 211 and the operation record information 212, the operation time totaling unit 322 that aggregates the operation time for each equipment in the analysis period, and the various operation logs of the operation record information 212. , Abnormal operation log determination unit 323 that determines whether it is steady or abnormal based on the presence or absence of alarm stop, and steady work time when there is no effect on the stagnation due to the occurrence of alarm stop etc. for the operation log determined to be steady. The steady time calculation unit 324 that calculates and calculates by product, equipment and operation status, and the operation loss calculation unit 325 that calculates and calculates the operation loss by the difference between the abnormal operation log and the regular work time, and the operation. The operation loss aggregation unit 326 for each alarm that aggregates the loss for each alarm in the operation record information 212, and the operation loss analysis history 221 and the operation time aggregation information for the results acquired, calculated, calculated, and aggregated by each of the above processing units, respectively. It is composed of 222, an operation loss influence degree information 223, and a display control unit 327 stored in the operation loss detailed information 224 and displayed on the input / output unit 100.

Next, the operation of each function in the operation loss analysis system 10 of FIG. 2 will be described according to the flowchart shown in FIG.

First, in order to analyze the factors that have a large effect on the operation loss from the operation results of various facilities at the manufacturing site, the user inputs, for example, the period of the operation results to be analyzed from the input screen as shown in FIG. , The analysis condition can be selected, the allowable working time can be input, and the process in the operation loss analysis system 10 can be started by clicking the execute button. Here, for the analysis conditions, select whether to specify the items used for classification of the operation results, and if "Specified" is selected, the items used for classification such as equipment, product type, processing date, etc. It is in the format of checking. Further, the allowable working time value is in a format in which the allowable threshold value when determining the operating loss is specified by the deviation ratio (%) or the deviation time (h) from the steady working time. In this embodiment, the analysis period (2019/10/1 to 2019/10/31) shown in FIG. 10 is input, the analysis condition is not specified, and "10 (%)" is selected as the allowable working time. The case where the input is input will be described below as an example.

Next, the data acquisition unit 321 acquires the information of the input information 210 based on the conditions such as the analysis period input by the user from the input / output unit 100 of the terminal or the like, and stores the information in the memory unit 310 together with the conditions. (S100). In this embodiment, it is assumed that the equipment processed product information 211, the operation record information 212, and the operation status information 213 shown in FIGS. 3 to 5 are acquired as the input information 210, and the various input values shown in FIG. 6 are acquired. , Will be described below. In FIG. 6, the analysis ID is an ID issued each time the execution button is clicked on the input screen of FIG. 10, and is an ID for managing the history of various analysis conditions and results input at the time of analysis. In addition, the "condition (equipment)", "condition (type)", and "condition (processing date)" in FIG. 6 correspond to the check boxes of the analysis conditions on the input screen of FIG. 10, and are checked. Set the flag as "1" for the items that are included and "0" for the items that are not included. Here, when "not specified" is selected, all three flags are set to "0".

Then, the operating time totaling unit 322 aggregates the operating time of each equipment corresponding to the analysis period from the equipment processed product information 211 and the operating record information 212, and stores the operating time in the memory unit 310 (S110). In the equipment processing product information 211 of FIG. 3, the record whose processing date corresponds to "2019/10/1 to 2019/10/31" is extracted, and the processing ID of the record is obtained from the operation record information 212 of FIG. Extract data and aggregate by equipment. Assuming that the operating time (h) for each equipment shown in FIG. 7 is generated by the above processing, it will be described below.

After that, the abnormal operation log determination unit 323 may have an operation loss due to the influence of the alarm stop based on the presence / absence of the alarm stop in the operation record information 212 and the operation loss calculation flag of the operation status information 213. A certain abnormal operation log is determined and stored in the memory unit 310 (S120). The detailed flow of this process is shown in FIG. 11 and will be described below.

First, the abnormal operation log determination unit 323 acquires a set of processing IDs for the same equipment / processing date of the equipment processing product information 211, and acquires the records having the processing IDs in the operation record information 212 in the order of the earliest start time (. S1200). In the equipment processing product information 211 of FIG. 3, the abnormal operation log determination unit 323 acquires the processing ID “100 to 105” for the equipment “M01” and the processing date “2019/10/1”, and the operation record information of FIG. The 212 is acquired, and the data in the first line is first read.

Next, the abnormal operation log determination unit 323 determines whether or not there is operation record data of the target to be abnormally determined (S1201), and ends the process when it is determined that there is no operation record data of the target to be abnormally determined (S1201). S1201; None), if it is determined that there is operation record data for which the abnormality determination is to be performed (S1201; Yes), the process proceeds to S1202. Here, the abnormal operation log determination unit 323 performs the processing after S1202 on the first line of the operation record information 212 in FIG.

Then, the abnormal operation log determination unit 323 determines whether or not there is an alarm stop log in the operation record data (S1202), and if it is determined that there is an alarm stop log, proceeds to the next process (S1202; yes) and stops the alarm. If it is determined that there is no log, the process proceeds to S1204 (S1202; none). In the operation record information 212 of FIG. 4, since the alarm ID of the data in the first line is blank, the abnormal operation log determination unit 323 determines that there is no alarm stop, and proceeds to the process of S1204.

After that, the abnormal operation log determination unit 323 determines whether or not there is an influence of the operation loss due to the alarm stop (S1204), and if it is determined that there is an influence of the operation loss due to the alarm stop, the process proceeds to the next process (S1204; Yes), if it is determined that there is no influence of the operation loss due to the alarm stop, the process returns to S1200 (S1204; none), and the next operation record data is read. In this process, since the influence of the operation loss is determined when the abnormality determination flag described later is set, the process returns to the process of S1200 at this point, and the data in the second line of the operation record information 212 in FIG. 4 is read.

The abnormal operation log determination unit 323 repeats the above processing up to the eighth line of the operation record information 212 in FIG. Since the alarm ID "A01" is set in the data on the 9th line, the abnormal operation log determination unit 323 determines that there is an alarm stop log in the processing of S1202, and proceeds to the processing of S1203.

Next, the abnormal operation log determination unit 323 sets the abnormality determination flag and stores it in the memory unit 310 (S1203). As shown in FIG. 12, the abnormality determination flag is associated with the actual ID and machining ID when the operation actual information 212 is read, and is "0 (no abnormality)" or "1 (abnormal)" for each operation status ID. Yes) ”is managed as a result of the judgment. The column of "# 1" in FIG. 12 shows the initial state of the abnormality determination flag, and "0" is set for each operation status ID. Then, "# 2" indicates the result of executing the processing of S1203 for the data in the 9th line in the operation record information 212 of FIG. 4, and the actual ID "1008" and the processing ID "102" of the operation record data are shown. , And all the error judgment flags of each operation status ID are set to "1". The symbol in parentheses is the alarm ID in the operation record data, and here, "A01" is set together with the flag.

Then, the abnormal operation log determination unit 323 determines whether or not there is an influence on the operation loss based on the abnormality determination flag (S1204). Here, the operation status ID in the operation record data (9th line in FIG. 4) is “W04”, and the abnormal operation log determination unit 323 sets the operation loss calculation flag of the ID in the operation status information 213 in FIG. Get "0". Here, the operation loss calculation flag is information for managing the abnormal operation log determination method for each operation status. In the abnormal operation log determination unit 323, "0" is the data in which the alarm stop occurs, "1" is the data of the same machining ID immediately after the alarm stop occurs, and "2" is the data of the next machining ID after the alarm stop occurs. Judge as an abnormal operation log. In the operation status information 213 shown in FIG. 5, the operation loss calculation flag of the operation status ID “W04 (alarm stop)” is “0”. The abnormal operation log determination unit 323 determines that the relevant data is abnormal because the status indicates the alarm stop itself. The operation loss calculation flag of the operation status ID "W03 (machining)" is "1". In the processing immediately after the alarm stop occurs, the operation loss due to the influence of the alarm may be included in the operation record data. Therefore, the abnormal operation log determination unit 323 determines that the data is abnormal. Furthermore, the operation loss calculation flag of the operation status IDs "W01 (condition setting)" and "W02 (setup)" is "2". After the alarm stop occurs, when processing the next product, preparation work such as condition setting and setup may be required more than during normal processing, so the abnormal operation log determination unit 323 has the corresponding data. Is determined to be abnormal. At this point, the operation status ID is "W04 (alarm stop)", and the value of the abnormality judgment flag in the status ID (W04 row in column # 2 in Fig. 12) is "1", so the abnormal operation log. The determination unit 323 determines that there is an influence on the operation loss, and proceeds to the process of S1205.

After that, the abnormal operation log determination unit 323 writes out the operation record data determined to have an abnormality as an abnormality determination list (S1205). Here, the actual ID "1008" and the operation status ID "W04" are acquired from the 9th line of the operation record information 212 in FIG. 4, and the alarm ID "A01" is acquired from the abnormality determination flag. As shown in the first line of, the data of the abnormality judgment list is generated.

Then, the abnormal operation log determination unit 323 clears the abnormality determination flag for the operation status (S1206), returns to S1200, and reads the next operation record data. Here, the abnormal operation log determination unit 323 clears the value of the operation status ID “W04” in the “# 2” column in the abnormality determination flag shown in FIG. 12, and transitions to the state in the “# 3” column.

By repeating the above processing, the transition of the abnormality determination flag as shown in FIG. 12 occurs, and the abnormality determination list shown in FIG. 13 is generated. Here, there are a plurality of alarm IDs "A02, A03" stored in the operation status IDs "W01 to W03" in the "# 9" column of FIG. 12, but there are a plurality of types in the operation record information 212. It means that the alarms of are continuously generated (data of actual IDs "1012" and "1013" in FIG. 4). In such a case, the abnormal operation log determination unit 323 similarly writes out a plurality of alarm IDs when the abnormality determination list is generated in the process of S1205 (actual IDs “1014 to 1017” in FIG. 13). In this way, the abnormal operation log determination unit 323 indicates the presence / absence of the alarm recorded in the operation record information 212 and the operation loss calculation flag indicating the determination method of the abnormal operation log for each operation status stored in the operation status information 213. Based on the above, the abnormal operation log in which the operation loss may have occurred due to the influence of the alarm is determined in the operation record information 212.

Next, returning to the processing flow of FIG. 1, the steady-state time calculation unit 324 extracts the operation record information 212 that was not determined to be an abnormal operation log in the processing of S120, calculates the steady-state work time for each operation status, and stores the memory. It is stored in the unit 310 (S130). Since the abnormality determination list determined to be the abnormal operation log in the processing of S120 is the actual ID "1008 to 1020" shown in FIG. 13, in the operation actual information 212 of FIG. 4, "1000 to 1007" other than these actual IDs. And "1021" are extracted as steady operation logs. Then, the steady-state time calculation unit 324 classifies these steady-state operation logs according to the operation status ID, takes statistical values, and calculates the steady-state work time. In this embodiment, it is assumed that the average value is used as the statistical value. For example, in the operation record information 212 of FIG. 4, when the steady time calculation unit 324 calculates the steady work time of the operation status ID “W01”, the actual ID “1000”, The average of the elapsed times "9 (minutes)", "11 (minutes)", and "10 (minutes)" of "1003" and "1006" is "10 (minutes)". Similarly, when the steady-state time calculation unit 324 calculates the steady-state work time of the operation status IDs "W02" and "W03", they are "20 (minutes)" and "30 (minutes)", respectively, and the data shown in FIG. 14 is generated. To. In this way, the steady-state time calculation unit 324 calculates the statistical value of the equipment operation time or the worker's work time for each operation status, and calculates the steady-state work time.

Then, the operation loss calculation unit 325 calculates the excess of the steady time for each operation status with respect to the abnormal operation log as the operation loss (S140). In this processing step, the operation loss calculation unit 325 first generates an allowable value for the steady work time of each operation status ID based on the steady work time allowance value input by the user from the input screen. Since "10 (%)" is input as the permissible value on the input screen of FIG. 10, it is considered that the permissible range (not regarded as an operating loss) is from the steady working time to the upside of 10%. Therefore, when the operation loss calculation unit 325 calculates the allowable time for each operation status ID in FIG. 14, the data of the allowable time shown in FIG. 15 is generated. Next, the operation loss calculation unit 325 calculates the operation loss based on the difference between the elapsed time of each operation record data and the permissible time for the abnormality determination list of S120. The operation loss calculation unit 325 acquires the elapsed time of the operation record information 212 of FIG. 4 from the abnormality determination list of FIG. 13, and takes the difference in the allowable time for each operation status of FIG. As a result, the operation loss data for each abnormal operation log shown in FIG. 16 is generated. Here, in the operation status "W04 (alarm stop)", since the data of the allowable time does not exist, the elapsed time in the operation record data is calculated as the operation loss as it is.

After that, the operation loss totaling unit 326 for each alarm allocates and totals the operation loss calculated in S140 according to the alarm type and operation status based on the number of occurrences, time, occurrence time, etc., and stores it in the memory unit 310 (S150). .. First, the operation loss totaling unit 326 for each alarm expands the operation loss calculation result of FIG. 16 by alarm ID and operation status, and generates the data shown in FIG. In FIG. 9, the product type, equipment, and processing date data can be generated by tracing the operation performance information 212 in FIG. 4 and the equipment processing product information 211 in FIG. 3 from the performance ID in FIG. Further, a plurality of alarm IDs affecting the operation loss of the actual IDs "1014-1016" in FIG. 16 are set as "A02, A03". In this embodiment, the result of dividing these operating losses into a plurality of alarm IDs is shown in FIG. As the method of allocating the operation loss, 100% may be allocated to the alarm immediately before the operation record data in which the operation loss has occurred, or the closer it is, the larger the weight may be allocated. After that, the operation loss totaling unit 326 for each alarm aggregates these operation loss distribution results for each alarm ID and operation status ID, and generates the data shown in FIG. In this way, the operation loss totaling unit 326 for each alarm totals the operation loss for each one or a plurality of types of alarms recorded in the operation record information 212, which indicates the cause of the equipment operation stoppage in association with the operation status.

Finally, the display control unit 327 obtains the analysis conditions input from the input unit 100 stored in the memory unit 310, the aggregation result of the operation time, the operation loss aggregation result for each alarm, and the operation loss calculation result, respectively. It is stored in the operation loss analysis history information 211, the operation time total information 222, the operation loss influence degree information 223, and the operation loss detailed information 224, and displayed in the input / output unit 100 (S160). An example of the output screen in this embodiment is shown in FIG.

At the top of this screen, the display control unit 327 is input by the input screen of FIG. 10 and displays the information of the analysis ID stored in the operation loss analysis history information 221 of FIG. When the analysis ID (analysis date and time) of this cell is switched by pull-down, the corresponding past operation loss analysis result can be displayed on the following screen.

Next, in the second upper part of this screen, the display control unit 327 shows the total operating time of the equipment in the operating time aggregated information 222 in FIG. 7, and the operating loss of all alarms in the operating loss impact information 223 in FIG. The total is displayed, and the result of calculating the operating rate based on these ratios is displayed. This makes it possible to grasp the ratio of operating loss during the analysis period, and it is possible to confirm whether or not there is a problem of a decrease in operating rate due to an alarm stop or the like.

Then, in the middle of this screen, the display control unit 327 displays the operation loss total result for each alarm ID and the operation loss breakdown for each operation status in the operation loss influence degree information 223 of FIG. In addition, by selecting "▼" in the first line of each item, it is possible to control the display order and the value filter. Further, the display control unit 327 displays an operation loss accumulation graph for each alarm and a cumulative ratio of all alarms to the operation loss as a Pareto chart in the lower part of the table. This makes it possible to grasp the alarms that should be dealt with preferentially during the analysis period, the magnitude of the impact, and the point of occurrence of the impact (operation status), and efficiently consider methods for reducing operation loss. Can be done.

Further, by selecting a cell in the operation loss impact table and clicking the "detailed display" button, the display control unit 327 displays the operation loss details corresponding to the alarm ID and the operation status ID for the cell on this screen. It can be displayed at the bottom. The output screen of FIG. 17 shows an example when the "Detailed display" button is clicked with the alarm ID "A03" and the operation status ID "W03 (machining)" selected. Lists the details of the operation loss of the alarm ID and the operation status ID. This makes it possible to identify detailed factors that have a large impact on operating loss.

As described above, in this embodiment, the steady-state time calculation unit 324 manufactures the operation status information 213 indicating the operation status including the operation state of the equipment or the work state of the worker, and the product or part for each operation status. There is no effect on the operation of the equipment or the work of the worker being stagnant due to the shutdown of the equipment based on the operation record information 212 in which the operation record of the above equipment or the work record of the worker is recorded. The steady work time is calculated for each operation status, and the operation loss calculation unit 325 determines the steady work time for each operation status based on the steady work time calculated for each operation status and the operation record information 212. The excess is calculated as an operating loss. Therefore, for example, even for the work of products / parts having low repeatability, it is possible to measure the degree of influence of the decrease in the operating rate on other work such as the stop of the equipment due to the alarm generated in the equipment. More specifically, even in factories that produce high-mix low-volume products, the alarm stop gives to other work based on the operation record data of each facility over time and the operation status such as the alarm stop that occurred in the facility. It is possible to evaluate including the influence of operating loss. As a result, it becomes possible to prioritize improvement measures for the types of alarms that have a large impact on operating loss and the operating status at that time, and to carry out improvement activities aimed at improving equipment operating rates and throughput. It will be possible to support.

100 Input / output unit 200 Storage unit 300 Calculation unit 210 Input information 211 Equipment processing product information 212 Operation record information 213 Operation status information 220 Output information 221 Operation loss analysis history information 222 Operation time summary information 223 Operation loss impact information 224 Operation loss details Information 310 Memory unit 320 Calculation processing unit 321 Data acquisition unit 322 Operation time totaling unit 323 Abnormal operation log judgment unit 324 Constant time calculation unit 325 Operation loss calculation unit 326 Operation loss totaling unit by alarm 327 Display control unit

Claims (8)

Operation status information indicating the operation status including the operation status of the equipment or the work status of the worker, and the operation record of the equipment or the work record of the worker for manufacturing a product or a part for each operation status are recorded. Based on the operation record information, the steady-state time calculation unit that calculates the steady-state work time that does not affect the operation of the equipment or the stagnation of the worker's work due to the outage of the equipment for each operation status,
An operation loss calculation unit that calculates an excess of the steady work time for each operation status as an operation loss based on the steady work time calculated for each operation status and the operation record information.
An operating loss analysis system characterized by having. The operating loss analysis system according to claim 1.
In the operation record information, one or a plurality of types of alarms indicating the cause of operation stoppage of the equipment are recorded in association with the operation status.
Operation loss totaling unit for each alarm that totals the operation loss for each alarm,
An operating loss analysis system characterized by having. The operating loss analysis system according to claim 2.
The operation record information is based on the presence / absence of the alarm recorded in the operation record information and the operation loss calculation flag indicating the determination method of the abnormal operation log for each operation status stored in the operation status information. Among them, the abnormal operation log determination unit that determines the abnormal operation log that may have caused the operation loss due to the influence of the alarm.
An operating loss analysis system characterized by having. The operating loss analysis system according to claim 1.
The steady time calculation unit calculates a statistical value of the operating time of the equipment or the working time of the worker for each operating status, and calculates the steady working time.
An operating loss analysis system characterized by this. It is an operation loss analysis method performed by a computer.
The steady-state time calculation unit has operating status information indicating the operating status including the operating status of the equipment or the working status of the worker, and the operating record of the equipment or the worker for manufacturing the product or part for each operating status. Based on the operation record information in which the work results are recorded, the steady working hours that do not affect the operation of the equipment or the stagnation of the worker's work due to the outage of the equipment are calculated for each operation status.
The operation loss calculation unit calculates the excess of the steady work time for each operation status as the operation loss based on the steady work time calculated for each operation status and the operation record information.
An operating loss analysis method characterized by this. The operating loss analysis method according to claim 5.
In the operation record information, one or a plurality of types of alarms indicating the cause of operation stoppage of the equipment are recorded in association with the operation status.
The operation loss totaling unit for each alarm totals the operation loss for each alarm.
An operating loss analysis method characterized by this. The operating loss analysis method according to claim 6.
The abnormal operation log determination unit is based on the presence / absence of the alarm recorded in the operation record information and the operation loss calculation flag indicating the determination method of the abnormal operation log for each operation status stored in the operation status information. Therefore, in the operation record information, the abnormal operation log in which the operation loss may have occurred due to the influence of the alarm is determined.
An operating loss analysis method characterized by this. The operating loss analysis method according to claim 5.
The steady time calculation unit calculates a statistical value of the operating time of the equipment or the working time of the worker for each operating status, and calculates the steady working time.
An operating loss analysis method characterized by this.

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