JP2783729B2 - Maintenance support device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a maintenance support apparatus for supporting a maintenance work of a plant or an education and training for the maintenance.

[0002]

2. Description of the Related Art Conventionally, at a site of a maintenance work of a plant, the maintenance work has been performed on the basis of written instructions, procedures, drawings, and the like.

[0003] In general, the equipment that constitutes a plant has an enormous number of points, and each of these equipment has an attached specification and
It has drawings, handling instructions, maintenance procedures, etc., and these specifications, handling instructions, maintenance procedures, and drawings make up a vast package of materials. Therefore, when performing a specific maintenance work on specific equipment of a plant, bring a part of the huge document package described above to the maintenance site, or take out necessary procedures, procedures, and drawings and copy them for maintenance. He was brought to the site for maintenance work.

[0004] If a part of the maintenance process is changed,
The adjustment between maintenance work was conventionally adjusted by humans.

[0005] Further, if a part of the procedure, procedure, or drawing is changed during the maintenance work, the changed procedure, procedure,
Checking or correcting the consistency of the drawings with other procedures, procedures, and drawings was done by humans.

[0006]

However, in the above-mentioned conventional method, a large material package must be brought to the maintenance site, and the portability of the material is lacking, which is inconvenient.
Also, it was not easy to accurately take out and copy only necessary procedures, procedure manuals, drawing data sheets and drawings. In particular, when a large number of maintenance work is performed within a limited period, or when the planned maintenance work is changed, it is extremely difficult to manage documents.

Further, when a part of a procedure, procedure, or drawing is changed, the other procedure, procedure, or drawing has to be manually corrected. It was very difficult to check the consistency, for example, no modification was made to the procedure manual. This contributed to the trouble at the plant.

[0008] In addition, regarding the process management, it has not been clearly determined what kind of human error is likely to occur due to the change in the process, and there has been a problem in preventing trouble before it occurs.

Further, the human error actually experienced by the worker in the maintenance work and the know-how acquired are valuable knowledge for those who perform the same work next time. The know-how was not accumulated, the same human error was repeated, or the know-how could not be systematically learned.

[0010] Since the above-mentioned activities such as site work, procedures, procedure manuals, drawing management, process management, and training were not performed based on a common database,
There was a problem that the efficiency could not be maximized as a whole integrated.

It is an object of the present invention to solve the above-mentioned problems related to the maintenance work of the conventional plant, to support the workers in the field work, to support the management of procedures, procedures and drawings, to support the process management, Comprehensive support for education and training
An object of the present invention is to provide a maintenance support device that can prevent occurrence of a human error beforehand.

[0012]

In order to achieve the above object, the maintenance support apparatus of the present invention specifies a work item, inputs a work result, and prepares necessary procedures, procedures, drawings, and A site terminal that outputs a work guide including precautions, a process database that stores data related to the process, a work information database that stores work information including procedures, procedures, and drawings, and video and audio data of the work site The stored non-character type site database, the human factor database storing the human error cases and the human error prevention guidance, the know-how database storing the know-how on the maintenance work including inspection and failure diagnosis, and the above-mentioned respective databases In combination, the data of a predetermined database can be input or changed by the on-site terminal, A common data area in which data of another database related to the input or change of database data can be automatically input or changed, and processes, work information, video / audio data related to the repair work specified by the site terminal , A human error case, a human error prevention guidance, and a know-how are edited on the common data area, and a guide creating system that outputs a work guide that provides necessary information along a repair work flow is provided. It is assumed that.

[0013]

The maintenance support device according to the present invention includes a work information database for storing procedures, procedure manuals, and drawings conventionally managed by paper, and a database in which process information conventionally managed by humans on paper is made into a database. It has a human factor database that stores human errors and human error prevention guidance, and a know-how database that stores a database of know-how related to inspection and failure diagnosis.

Further, the maintenance support apparatus of the present invention has a guide creation system, a process management system, a change management system, and an education and training system for making the above-mentioned databases organically linked and functioning.

[0015] In the above guide preparation system, when a maintenance work item is specified by the site terminal, process information related to the item is input to the process table of the process database, and a work information database, a human factor database, and a know-how database are provided. And retrieve relevant procedures, procedures, drawings, human error cases, human error prevention guidance, know-how, etc. Further, the information is edited and output as a work guide.

Thus, the conventional complicated work of taking out necessary documents from an enormous amount of material packages by a manual operation is conventionally performed by a computer, and a work guide including necessary information on maintenance work is promptly provided to the worker. Can be provided. The above-mentioned process management system manages process information related to maintenance work input from the site terminal, checks the consistency of each process when there is a process change, and what kind of human error due to similar process change in the past. Can be retrieved to alert the worker.

Thus, the necessity of the process change and the possibility of the human error can be weighed, and the human error due to the process change can be prevented.
The above-mentioned change management system automatically retrieves the relevant procedures, procedures, and drawings from the work information database when the procedures, procedures, and drawings have been partially changed due to the circumstances at the site, and automatically or automatically uses the change management terminal. The contents of the related documents can be corrected by input from. As described above, since the related documents can be taken out of the work information database without omission by the computer, it is possible to reduce the possibility of a plant trouble due to the omission of the correction of the documents.

The above-mentioned education and training system stores the individual training and training history information of the trainees, specifies the trainees and the training items, and retrieves relevant procedures, procedures and drawings from the work information database. It is possible to extract past human error cases, human error prevention guidance and know-how from the human factor database and the know-how database and provide them as training materials.

As a result, the trainee can obtain necessary training materials and can systematically learn past human error cases and know-how. Further, by combining the training materials and the video / audio data of the site database, more effective training can be performed.

[0020]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is intended to support maintenance work of a plant, including procedures, procedures and drawings, process information, human error cases related to maintenance work, human error prevention guidance, and know-how related to maintenance work. This is a maintenance support device that is configured so that the education training history information of a person who undergoes education training is stored in a database, and these are comprehensively managed by a computer so that relevant information can be quickly and completely extracted. In particular, this maintenance support device reflects this work item in the entire process by specifying the maintenance work at the site terminal, and also relates to related procedures, procedures, drawings, human error cases, human error prevention guidance, know-how, A function that provides workers with work guides including video and audio data, and when a part of a process is changed, this is reflected in the entire process, and a search is made for human error cases that can be caused by the process change Function to make accurate judgments on process changes by performing a search, and when a part of the procedures, procedures and drawings are changed, search the relevant documents in the database and make corrections to the relevant documents without omission By identifying the trainees and the training items, a function that enables It has a function to search for documents, procedures, drawings, human error cases, human error prevention guidance, and related video and audio data in their respective databases, and provide these to trainees as training materials. Is what you are doing.

An embodiment of the present invention will be described below with reference to the accompanying drawings. FIG. 1 shows the overall configuration of a maintenance support device according to a first embodiment of the present invention. The maintenance support device 1 according to the present embodiment includes a process database 2 storing process information.
A work information database 3 in which procedures, procedures, and drawings are made into a database; a human factor database 4 in which human error cases and human error prevention guidance relating to each maintenance work are made into a database;
A know-how database 5 that stores know-how related to each maintenance work, a site database 6 that stores non-character data such as video / audio data of the site, and common data that enables the exchange of data by combining the databases. It has an area 7, a guide creation system 8 for operating each database in association with each other, and a site terminal 9 for performing input and output.

The function of the guide creation system will be described below with reference to FIG. FIG. 2 is a block diagram showing a processing flow of the guide creating system. In step 100, the work item of the maintenance work is designated by the worker at the site terminal 9. As a result, the guide creation system 8 accesses the work information database 3 to search for related procedures, procedures, and drawings, and extracts data from the common data area 7 (steps 110 and 120). Subsequently, the guide creation system 8 accesses the process database to reflect the work items in the process (not shown), and
, The human factor database 4 is accessed to search for human error cases and human error prevention guidance related to the maintenance work, and the data is extracted to the common data area 7. Next, step 140
In, related know-how is extracted from the know-how database 5 onto the common data area. At this time, if necessary, relevant video / audio data is extracted from the site database 6. Next, in step 150,
The various data described above are edited on the common data area 7 by the guide creation system 8 and output to the site terminal 9 as a work guide. The guide creation system 8 outputs necessary and sufficient procedures, procedures, and drawings related to the maintenance work to the on-site terminal 9, thereby avoiding the cumbersome document management of the plant and taking the documents. Plant trouble due to the difference can be prevented beforehand. Furthermore, along with procedures, procedures, and drawings, precautions on work such as human error cases and know-how related to the work are presented to the worker, so that the same work mistake is prevented, and the knowledge of the skilled worker is It can be used effectively.

Next, specific input / output will be described using the screen of the site terminal 9. FIGS. 3 and 4 specifically show input / output screens at the site terminal 9 when the tightening work of the pump flange is selected. FIGS. 3 and 4 show a flow of a series of processes, which are divided into two for convenience of display of the drawings. Screen 3 at the end of FIG.
Continue to first screen 4 of

Referring to FIGS. 3 and 4, step 200 represents the step of selecting a large work item. In the maintenance work of the plant, there are various kinds of maintenance work other than the maintenance work of the pump. These various works are displayed on the screen 1 and the operator can freely select one of them. In this case, the operator selects “XXX pump overhaul”. The next step 210 shows the step of selecting a detailed work item. When the disassembly and inspection of the XXX pump is designated in step 200, the entire procedure for disassembling and inspecting the XXX pump is displayed on the screen 2. The operator selects “Flange bolt / nut tightening” from these. As a result, the guide creation system 8 functions as described above with reference to FIG. 2, and as a result, a work guide including work information is output on the screen of the site terminal 9 or to an output device (step 220). In this operation, in the next step 230, a check sheet for notes on the tightening operation of the flange bolts and nuts is output as shown in screen 3. The operator prepares for the work while checking each item of the check sheet. All check items are "YES"
Is reached, the next confirmation screen 4 is displayed (step 240). The worker confirms the screen for prompting the start of the work, enters the actual work, and inputs the “work completed” item on the screen 4 after the work is completed. As a result, the maintenance support apparatus 1 outputs the recording format (step 250). In the next step 260, the operator inputs work results into the output check sheet (screen 5) for recording. The check sheet in which the work results are input becomes a construction report as it is, and the data is accumulated in the human factor database 4 and the know-how database 5.

Next, a description will be given of a maintenance support apparatus according to the first embodiment in which a process management function, a change management function for procedures, procedures, and drawings, and an education and training function are added. FIG. 5 shows the configuration of a maintenance support device to which the above-mentioned process management function, change management function for procedures, procedures, and drawings, and an education and training function are added. In FIG. 5, the same parts as those in FIG. The maintenance support device 10 of the second embodiment has an education and training database 11 in addition to the process database 2, the work information database 3, the human factor database 4, the know-how database 5, and the site database 6. The training database 11 stores training history information for each trainee.
In addition, it has a common data area 7 for enabling the exchange of data of these databases as in the first embodiment. Further, the maintenance support device 10 has a process management system 12, a change management system 13, and an education and training system 14 in addition to the guide creation system 8.
In order to operate each of the above systems, in addition to the site terminal 9, a process management terminal 15, a change management terminal 16, and an education and training terminal 17 are provided.

When the process is changed, the process management system 12 reflects the changed process in the entire process, checks the consistency with other processes, accesses the human factor database 4, and accompanies the process change. A case of a human error is retrieved and output to the process management terminal 15. FIG. 6 shows a processing flow of the process management system 12. In step 300, a process change input process is performed,
Next, in step 310, a specific process to be changed is input.
In the next step 320, the process management system 12 accesses the process database 2 to check the consistency between the processes, and then checks the human factor database 4
To search for related human error prevention guidance. Next, in step 330, the changed process and the related human error prevention guidance are output to the process management terminal 15. According to the process management system 12, the operator can obtain a cautionary note accompanying the process change, or can make an accurate judgment on whether or not the process change is necessary.

The change management system 13 searches the work information database 3 for other procedures, procedures and drawings related to the partial changes when the procedures, procedures and drawings are partially changed. Then, the consistency can be checked and corrected so that the consistency is maintained automatically or by the change management terminal 16. FIG. 7 shows a processing flow of the change management system 13. As shown in FIG. 7, in step 400, the input of the change of the procedure, the procedure, and the drawing is processed, and in the next step 410, the changed portion is specified. Then step 4
At 20, the change management system 13 searches the work information database 3 for relevant procedures, procedures, and drawings,
The consistency between related documents is checked on the common data area 7. As a result, in the next step 430, the change result is output to the change management terminal 16. If necessary, the document can be automatically corrected by the computer, or the document can be manually corrected by the change management terminal 16. As a result, it is possible to prevent a situation in which there are many related documents, and when some documents are changed, other documents to be corrected are not corrected and cause a trouble in the plant.

When the trainee and the training item are specified, the training system 14 extracts the training history information from the training database 11 of the trainee, furthermore, the work information database 3, the human factor database 4, and the know-how database. The relevant procedures, procedures, and drawings, human error cases, human error prevention guidance, and know-how are extracted from 5, respectively. FIG. 8 shows a processing flow of the education and training system 14. First, in step 500, trainees and training items are input. Next, in step 510, the education / training system 14 accesses the education / training database 11, searches the training / training history information of the trainee, and also accesses the work information database 3, the human factor database 4, and the know-how database 5. Search for relevant procedures, procedures, drawings, human error cases, know-how, etc. Next, in step 520, the educational training material is output to the educational training terminal 17, so that the educational training can be performed. Next, in step 530, input the results of education and training,
In step 540, the evaluation is performed, and in step 550,
These training results and evaluations are stored in the training database 11
Register with. Through the above processing, the trainee can quickly obtain teaching materials necessary for education and training, and can systematically learn past experiences such as human error cases.
At this time, if necessary, images and
If voice data is taken out and used in combination with the above-mentioned materials for education and training, more effective education and training can be performed.

The on-site terminal 9 and the process control terminal 15
And the change management terminal 16 and the education / training terminal 17 have been described as separate terminals for easy understanding. However, these terminals may be one workstation, and the above-described various processes may be performed on the workstation. The good is clear.

[0030]

As is apparent from the above description, the maintenance support device of the present invention has a work information database, a human factor database, a know-how database, a site database, and a guide creation system. Is necessary and sufficient for maintenance work.
Procedures and drawings can be promptly provided to the operator, and the inconvenience of the portability of documents can be solved, and complicated document management and troubles due to this can be prevented. In addition, the work results can be accumulated as human error cases and know-how, and the skill of the worker can be improved. In addition, by having a process database, human factor database, and process management system, when a part of the process is changed, the consistency between the processes is checked, and the human error case accompanying the process change is further confirmed. Can be provided to workers. As a result, it is possible to prevent troubles due to interference between processes beforehand, present a human error case that can be caused by a process change to an operator, and make an accurate decision on the process change. In addition, the work information database and change management system provide
When a part of the procedure manual / drawing is changed, it is possible to search for all the documents to be corrected in accordance with the change, and to correct the related documents without omission. Thus, it is possible to prevent a plant trouble due to omission of correction of documents. In addition, by having a work information database, a human factor database, a know-how database, an education and training database, and an education and training system, by specifying trainees and education and training items, guidance for preventing human error is provided. Educational training materials including training and know-how can be provided to trainees, enabling efficient training and systematic learning of past experiences.

That is, according to the present invention, it is possible to obtain a maintenance support device that combines the various effects described above, facilitates on-site work, and prevents a plant trouble before it occurs.

[Brief description of the drawings]

FIG. 1 is a diagram showing an entire configuration of a maintenance support device according to a first embodiment of the present invention.

FIG. 2 is a block diagram showing a processing flow of a guide creation system.

FIG. 3 is a diagram showing a processing flow of a specific work example on a screen of a site terminal.

FIG. 4 is a diagram showing a processing flow of a specific work example on a screen of a site terminal.

FIG. 5 is a diagram showing an entire configuration of a maintenance support device according to a second embodiment of the present invention.

FIG. 6 is a block diagram showing a processing flow of a process management system.

FIG. 7 is a block diagram showing a flow of processing of the change management system.

FIG. 8 is a block diagram showing a processing flow of the education and training system.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Maintenance support device 2 Process database 3 Work information database 4 Human factor database 5 Know-how database 6 Site database 7 Common data area 8 Guide creation system 9 Site terminal 10 Maintenance support device 11 Education and training database 12 Process management system 13 Change management system 14 Education Training system 15 Process control terminal 16 Change control terminal 17 Education and training terminal

Claims (2)

(57) [Claims] A work item is specified, a work result is input,
A site terminal that outputs work guides containing necessary procedures, procedures, drawings, and precautions for work, a process database that stores data on processes, and work information that contains procedures, procedures, and drawings A work information database, a non-character site database that stores video and audio data of the work site, a human factor database that stores human error cases and human error prevention guidance, and work related to maintenance work including inspection and failure diagnosis The know-how database storing the know-how and the respective databases are combined, and the data of a predetermined database can be input or changed by the on-site terminal, and the data of the related database is automatically input or changed by inputting or changing the data of the database. Can be entered or changed Data area and process related to the repair work specified by the site terminal, work information, video and audio data, human error cases, human error prevention guidance, know-how are edited on the common data area, and the flow of the repair work And a guide creation system that outputs a work guide that provides necessary information along the line. 2. A site terminal for specifying a work item or a training item, inputting a work result, and outputting a work guide including necessary procedures, procedure manuals, drawings, and work precautions; A process management terminal that inputs and outputs information for processes, a process database that stores data on processes, a work information database that stores work information including procedures, procedures, and drawings, and an input and output of information related to education and training. Education / training terminal to be used, education / training database that stores trainees' training history information, non-textual site database that stores video and audio data for work sites or training, human error cases and human error prevention guidance And human know-how related to maintenance work including inspection and failure diagnosis. The know-how database and the respective databases are combined, and data of a predetermined database can be input or changed by the on-site terminal, and data of another related database is automatically input or changed by inputting or changing the data of the database. Editable common data area and process related to the repair work specified by the site terminal, work information, video / audio data, human error case, human error prevention guidance, know-how on the common data area, A guide creation system that outputs work guides that provide necessary information along the flow of repair work, a process management system that manages process changes, and manages changes in work information, including procedures, procedures, and drawings A change management system and information on the training history of individual trainees and TamotsuOsamu support device being characterized in that and a training system for managing execution information of education training.