JP5509175B2 - Equipment / equipment operation manual dynamic maintenance management system - Google Patents

Description

  Equipment / device operation management and maintenance

  Equipment and devices used in various business activities, including production activities, are prepared and designed according to the purpose and conditions of the business activities, or by purchasing compatible manufacturer standard products. At this time, the specifications of the facility / equipment, the usage of the facility / equipment are determined, and the education method for the people who actually use the product is also determined with consideration so as to optimize the whole. In addition, if it is clear that the facility will be expanded or remodeled in the future, the specifications and methods for change will also be considered.

  Among them, the operation manual for properly using the completed facilities and equipment is as important as the functions, performance, and reliability of the facilities and equipment, and it is necessary to accurately realize the purpose of business activities. The content must be accurate and easy to understand. For this reason, various efforts have been made to produce an operation manual.

  For example, in addition to formal measures such as terminology, sending kana, numbering method of chapters and charts, unification of formats and typefaces, display with graphs, charts and illustrations, bulleted items, reflection of design information and equipment specifications In addition, it has been devised in terms of content, such as incorporating expert know-how and reflecting past failure cases and success cases. Conventionally, an operation manual reflecting these ideas has been regarded as an excellent operation manual.

  However, at the time of initial creation, even if an excellent operation manual is created by borrowing the power of experts, once the equipment / device is in operation, it is almost impossible to get the help of an expert to maintain the manual. In addition, the operation manual is rarely corrected accurately for various corrections / changes in the operating conditions.

  In general, at the time of initial creation, there is a lack of maintenance after the start of operation, although there is a large involvement of experts. In particular, due to the characteristic of the operation manual that the management is left to the site, there may be some reworking by the person in charge of the site, but it can be said that the operation manual is sufficiently maintained and managed after the facilities and equipment are in operation. There is no situation.

  In response to such problems, for example, Patent Documents 1, 2, and 3 describe (i) reflection of changes in laws and regulations, (ii) on the operation manual (instruction manual) relating to equipment and devices created in the initial stage. Identify and set the latest information when there are multiple information related to the same device. (Iii) When information related to the same equipment / device is divided and managed, Ensuring version consistency is disclosed.

JP 2003-91531 A JP 2004-110149 A JP 2007-34573 A

  However, these patent documents do not consider correcting the deviation from the operation manual caused as a result of operating the equipment.

  The above situation will be described with reference to FIG. The operation manual 8 of the newly installed equipment / device is referred to equipment specifications 3, operation plan 4, manual creation standard 5 by the knowledge 7 of the designers and experts at the initial setting 1 and (a) manual creation standard , (B) Utilization of existing similar manual 6 and (c) Reflection of equipment specifications and operation plan, etc. are devised to operate the equipment / device in an optimal situation. However, even if the facilities / devices actually operate and the environmental conditions inside and outside the facilities / devices change, there is no mechanism 10 for feeding back the results to the operation manual. For this reason, there is a discrepancy with the manual created at the beginning of operation.

Specifically, there are the following problems.
(1) Despite changes in operating conditions (external conditions, internal conditions), operations may not follow and may lead to situations such as unfulfilled objectives and reduced efficiency.
(2) If the above overlaps, the operation manual becomes obsolete, and the contents of the manual may not be reflected in the operation (operation away from the manual may become normal).
(3) The person in charge at the site may devise and operate its own because the operation manual is different from the actual situation, operation that violates the design specifications, operation that leads to deterioration of the quality of products and services, Operations that may lead to accidents may occur.
(4) In addition, due to the unique operation by the person in charge in 3), an excessive burden is applied, which may shorten the life of the equipment or cause unexpected troubles.
(5) The function or quality of the product or service provided by the facility may be reduced.

  The present invention is for solving the above-mentioned problems.

  The following measures are taken as means for solving the problems.

  In order to modify the operation manual according to the operation of the device, specify the items to be modified according to the operation of the device in the operation manual, collect information on the operation of the device, and modify the items based on the collected information To correct the operation manual.

  According to the present invention, the contents of the operation manual can be corrected in accordance with changes in the operation conditions.

Thereby, the following further effects can be expected.
(1) Since the contents of the operation manual follow changes in the operation conditions, it is possible to operate the equipment / device accurately without imposing an excessive burden on the person in charge of operation. As a result, it is possible to improve or maintain the quality of products and services provided by the facilities and apparatuses.
(2) Since the burden on the facilities / equipment can be reduced, it is possible to expect a reduction in failure and a longer service life of the facilities / equipment, thereby reducing the total cost of ownership (TCO).
(3) By optimizing and improving the efficiency of the operation of the equipment / device, it is possible to reduce energy consumption and contribute to solving global warming problems.
(4) By providing feedback on the evaluation of products and services provided by users, it is possible not only to continue providing products and services of the required quality, but also to avoid excessive quality by feeding back user evaluations. It may be possible to realize characteristics that cannot be grasped only by mechanical measurement of the functions and quality of the products or services provided.
(5) It is possible to save records of changes, reasons, date and time of change of the operation manual, and it is possible to prove the validity of the purpose / process of the equipment / device. Depending on the product provided, it may be necessary to prove the validity of the equipment / device or process, but according to the present invention, even in such a situation, the measured value, operation record, etc. relating to the equipment / device. It can be used for proof of validity by storing it together with.

Description of prior art Overview of problem solving means Initial settings in “Management Standards Maintenance Method” Illustration of “Maintenance method of“ Management Standard ”” Explanatory diagram of “Measurement of driving status and grasp of results” Illustrations / supplements for “Measurement of driving status / Results” Illustration about "feedback from users of products and services" Illustrations / supplements for feedback from users of products and services Illustration of “Simulation Function” Illustrations / supplements for "simulation function" Maintenance of "Production line operation manual" Maintenance and management of “production line operation manual” and operation manual update for molding shop Maintenance and management of “production line operation manual” and operation manual update for molding shop Maintenance of "manufacturing line operation manual", operation manual update of molding shop, change of molding shop process time Hardware diagram of operation manual maintenance management device

<Overview of Example 1>
The outline of the present embodiment will be described with reference to FIG.
(1) “Preparations when creating a new operation manual ((d) Specifying adjustment items)”
In order to dynamically maintain and manage the equipment / equipment operation manual based on the situation after the operation, when the equipment / equipment operation manual is created, the items to be adjusted when the operating conditions change are identified. Specify the contents in the manual. Further, this information is stored in a database.

  In this embodiment, work timing 17, work target 18, and work set value 19 are specified as adjustment targets.

In addition, a database of equipment specifications 3 for the target equipment / device or its parts is prepared so that necessary information can be referred to.
(2) “Preparation when creating a new operation manual ((d) parameter specification)”
Various numerical values (parameters) necessary for maintaining the operation manual (changed depending on the situation) are clearly indicated in the manual, and this information is stored in the database. In this embodiment, the work timing 17, work object 18 and work set value 19 are adjustment objects, and the respective values (starting time, XXX, M.N ° C.) are parameters.
(3) “Measurement of driving conditions and grasp of results”
For the dynamic maintenance management 12 of the operation manual after the start of operation, (e) measuring the operation status and grasping the actual results, whether the equipment / device is operated under the conditions assumed in the operation manual, Alternatively, it is checked whether the equipment / device is used within the expected range. In this check, the information on the facilities / devices sensed by various sensing devices is compared with the reference information set when the operation manual is created to check whether it is within the expected range. If the sensing result has a deviation, the operation manual 8 is corrected and an instruction is issued to create the operation manual 8v.
(4) “Feedback from users of products and services”
Feedback (f) such as satisfaction degree is obtained from the user 13 of the product or service provided by the facility, and after performing certain statistical processing such as satisfaction distribution, the contents of the operation manual 8v as necessary Reflect 15
(5) "Simulation (g)"
In order to reflect 14 changes in the operation plan 4 associated with changes in operating conditions (external conditions, internal conditions) in the operation contents of the related equipment / devices in advance, the equipment specifications 3 and the changed operating condition information are also included. Then, the simulation (g) is performed to identify the changed part and the changed contents and reflect them in the operation manual 8v.

The outline of the present embodiment is as described above. Next, the details of the outline will be described. <Details of Example 1>
With reference to FIGS. 3A and 3B, the “management standard” maintenance method defined in the Law Concerning the Rational Use of Energy (hereinafter referred to as the “Energy Saving Law”) will be described.
(1) Regulatory requirements of the Energy Conservation Act The Energy Conservation Act is a law that promotes the rational use of energy. There are various regulations. Among these are the establishment of “management standards” for facilities and devices that use energy, and the operation of facilities and devices according to those “management standards”. “Management standard” corresponds to an operation manual for equipment and devices for energy saving.
(2) Configuration items of management standards As a promotion item for energy conservation activities based on “judgment standards” established by the country, the creation of management standards and the setting of management targets are required. The “Management Standard” defines measures in four phases: (i) management, (ii) measurement / recording, (iii) maintenance / inspection, and (iv) new establishment of each applicable facility / equipment. The start / stop of equipment, set temperature, measurement procedure, etc. are to be described so that they can work according to the work procedure, and to be determined for each equipment / device, or for each equipment / device group performing the same purpose / operation. It has become. (3) Overall configuration of the embodiment of the present invention (preparation for initial creation)
In the present embodiment, the creation support / maintenance management of the “management standard” compliant with the Energy Saving Law will be described taking air conditioning in a large store as an example. This air conditioning is assumed to be composed of a plurality of packaged air conditioners. It is assumed that each package air conditioner has the same capacity and can be started and stopped independently.

  FIG. 11 shows a hardware configuration diagram of a manual maintenance management device that performs maintenance of the manual. This apparatus includes a calculation unit (CPU) that performs various processes, a storage unit (hard disk) that stores various types of information, and an interface unit that communicates with the outside. Here, the interface unit is installed in an external facility or apparatus, and is connected to a sensor that collects information on the facility or apparatus.

  FIG. 3A is an explanatory diagram of the initial setting of “management standard”. In order to dynamically maintain and manage the “management standard” of the equipment / device according to the operation status, it is necessary to determine the items to be changed and specific parameters at the initial setting.

  The flow of the “initial creation” process reflects the design specifications, equipment specifications 3 and operation plan 4 for each facility / equipment prepared in advance in the “management standard”. create. The contents 23 of the equipment specification 3 are information relating to the supply of air conditioning capability such as the relationship between the power consumption and air conditioning capability of the packaged air conditioner, the installation position, and the shared floor area. The contents 24 of the operation plan 4 are store operation plans, and are information on air conditioning loads such as opening / closing times by day of the week, estimated number of visitors, normal outside temperature, and target set temperature.

  Under these assumptions, facilities and devices will be operated and maintained based on the operation manual 8. To maintain this manual dynamically according to the operation status, the operation manual No. 8, which information is to be changed must be determined in advance at the time of initial setting.

In the case of “Management Standards” 21 for packaged air conditioners complying with the Energy Conservation Law, (i) management, (ii) measurement / recording, (iii) maintenance / inspection, and (iv) new operations, the contents of operations and their management It becomes a list form consisting of standards and remarks. In this operation manual, items that are dynamically changed during facility operation / maintenance management are: startup time 25-1, outside temperature 26-1, standard temperature 26-2, number of customers 26 Let -3 be a variable. Also, the temperature judgment time 27-1 and the visitor number variation unit 27-2 that affects the adjustment of the number of operating air conditioners are also variables.
(4) Overall configuration of this embodiment (maintenance management)
Fig. 3 (B) describes how to maintain the operation manual dynamically during actual operation. In accordance with the created operation manual 8v, the package air conditioners 29-1, 29-2, 29-3... 29-n of the large store 22 are operated. Based on the operation plan of the day (opening time, expected number of customers visiting the store, set temperature, etc.) and the outside air temperature 30, the packaged air conditioners 29-1, 29-2,... 29-n are started and the target temperature is set. At this time, the temperature 28-1, 28-2, 28-3 ... 28-m in the store is measured, and the package air conditioner 29-1,29-2 ... 29-n is determined according to the deviation from the set temperature. Operation / stop or output adjustment may be performed. In addition, the number of customers visiting the store may be ascertained, and the number of package air conditioners may be adjusted. However, even when the operation based on the operation manual 8v is performed, if a deviation from the target temperature often occurs, the start time 25-1, the set temperature 26-2, the outside air temperature determination time 27 described in the operation manual 8v -1 etc., it is necessary to adjust the number of customers to the standard store 26-3 and the number of customer increase / decrease number 27-2 of the increase / decrease in the number of package air conditioner operation. For this purpose, (e) the driving situation is measured and the results are grasped.

  (F) As a feedback from users of products and services, whether or not the air conditioning itself is appropriate even if there is no temperature deviation, ask the shopper who actually uses the store for a questionnaire 32, Have the diary 33 describe the air-conditioning experience and examine the accuracy of the air-conditioning method (set temperature, number of operating package air conditioners 29, output, etc.).

  Furthermore, (g) the operation method when the operation deviates from the actual operation conditions is required by the simulation function, the number adjustment and the output adjustment are the temperature in the store 29-1, 29-2 ... 29 -Determine the sensitivity of how it affects n, etc., and obtain back data when changing each operation standard.

  These functions are used singly or in combination to achieve the target “dynamic maintenance of“ management standard ””. Each function is described in the following sections.

  Note that the set temperature is not uniform in the store and may vary depending on the sales floor (for example, the temperature of the fresh food section is set lower). However, for simplicity of explanation, in this embodiment, the set temperature in the store is It shall be uniform.

(5) Measurement and grasping of driving situation of this embodiment (e) Measurement and achievement grasping of driving situation will be described individually with reference to FIG. Measure the measured temperatures 28-1, 28-2, 28-3, ... 28-n at each point, calculate the deviation from the target set temperature, and calculate this for a certain period (1 week to 1 month) continue. Based on the collected deviation data, the average value and standard deviation are calculated (function 41). Since it is possible to quantitatively grasp the situation where the set operation pattern deviates from the actual state from the average value and the standard deviation, the optimization of the operation pattern of the packaged air conditioner is measured based on these data (function 42).

  Specifically, if the temperature deviation is negative, the air conditioning capacity is excessive, and if the temperature deviation is positive, the air conditioning capacity is insufficient. Therefore, referring to the operation plan 4, an appropriate operation pattern “air conditioning capacity” is estimated ( Function 42). As a result, an air conditioning capability difference 43 including the basic pattern 44-1 and the correction pattern 44-2 of the air conditioning capability is obtained. By dividing this difference 43 by the air conditioning capability of each packaged air conditioner obtained from the device specifications 3, the change in the number of operating units and the capability can be understood, so that the changed operation schedule can be obtained.

  Write this schedule in the form of change 46-1 for startup time 25-1, change 46-2 for set temperature 26-2, change 46-3 for temperature judgment time 27-1, and change "management standard"・ Promote optimization.

  Next, the details of the procedure for changing the air conditioner operation pattern from the statistical value of the temperature deviation will be described with reference to FIG. The degree of nonconformity between the air conditioning load and the air conditioning capacity is determined from the deviation of the air conditioning status in the store, and the enthalpy difference obtained using the wet air diagram and the spatial volume of the target part from the respective temperature and humidity deviations relative to the set value Thus, the adjustment amount of the air conditioning functional force necessary to eliminate the nonconformity is known (function 47). The adjustment amount is optimized for the operation pattern of each packaged air conditioner obtained from the operation plan 4 (function 42).

  As a result, the operation pattern of the air conditioner is changed from the basic pattern 44-1 to the correction pattern 44-2. As a result, the capacity of the air conditioner required in each time zone can be obtained. Refer to the specifications 3 of each equipment and consider the capacity of each applicable equipment, and obtain the air conditioning function power obtained. Accumulate the capacity of each air conditioner to meet the requirements and obtain an operation plan.

Regarding the air conditioning functional force deviation obtained in function 47, the individual air conditioner operation patterns 49-1a, b, c, ... that constitute the air conditioner operation pattern 48-a before the change are 49-2a, b, c It will be changed to ... This change is reflected in the operation manual. (6) Feedback from product / service user of this embodiment (f) Details of feedback from the user of product / service will be described individually with reference to FIG. In the case of the present embodiment, users of products and services are customers who visit the store and employees who work at the store. The feedback information is the comfort of air conditioning. In the case of a customer who visits the store, the customer obtains the comfort of the air conditioning by a questionnaire given at the cash register, and in the case of an employee, basically, it is acquired from the employee diary. Select feedback (hot, slightly hot, comfortable, slightly cold, cold, damp, dry, etc.) in advance so that the feedback information is filled in using the same criteria. It will be in the form of getting. This is digitized by the function 51 and the statistical processing 52 is performed. In statistical processing, the average and moving average are obtained, and the degree of correlation with the number of visitors, the external temperature, the season, and the air conditioning capacity in the corresponding time zone is obtained. By grasping the relationship between the user's feeling and the air conditioning capability, the start time, the reference outside air temperature, and the number of packaged air conditioners operated are adjusted. As a result, a trade-off 53 between energy use and user comfort becomes possible, and the “Management Standard” 21 changes to the start time 25-1, 54-1 changes to the reference outside temperature 26-1, 54-2, air conditioner Write the change 54-3 to the number of customer visits 27-2, f) feedback from users of products and services. This function can reflect the user's feeling that cannot be determined only by the equipment specifications 3 and the operation plan 4 in the change of the “management standard”, and is also a function that helps to balance comfort and energy consumption. It is.

  In this example, a questionnaire and a diary were used as means for feeding back the user's feeling. However, according to recent technology, it is possible to adopt a method that allows real-time input such as the use of a mobile terminal. It is also possible to shorten the time for feedback of the person's feeling.

  Next, with reference to FIG. 5 (B), a supplementary explanation will be given regarding the processing contents of the feedback results of store customers and employees who are service recipients.

  The user's comfort feedback numerical value 51 obtained from the customer questionnaire 32 and employee diary 33 is added to the date / time zone and place where the information was obtained to obtain a list 51d. This is processed by the user feedback statistical processing 52 as an input 51i. The statistical processing is collectively performed for each data acquisition place and date / time zone when the feedback data is acquired. When the amount of data is large, more accurate results can be expected if classification is possible even when the outside air temperature and the number of store visitors are different.

  In addition, when the number of visitors can be grasped in real time with sensors installed at the entrance of the store, or when the user's feeling can be grasped in real time with a mobile terminal as described above, the moving average is calculated for a short time. Process after absorbing the fluctuations.

  The cross-correlation between the air conditioning functional capability corresponding to each data group is obtained, and the sensitivity of the air conditioning functional capability to the user feedback (comfort level) 51 is obtained.

この結果、相互相関係数τが、制限値(例えば0.5)以上であることを確認して、快適度の偏差Δｘと、それに対応する空調機能力の偏差Δｙを求め、感度 Δｙ/Δｘを求めて、空調機能力の調整量を求める。

As a result, it is confirmed that the cross-correlation coefficient τ is equal to or greater than a limit value (for example, 0.5), and a comfort level deviation Δx and a corresponding air-conditioning function force deviation Δy are obtained to obtain a sensitivity Δy / Δx. Then, find the adjustment amount of the air conditioning function.

The operation manual can be maintained by writing the operation manual so as to adjust the air conditioning function by multiplying the adjustment amount by the deviation of the sensitivity comfort level.
In addition, when the cross-correlation τ between the comfort level and the air conditioning functional force obtained by the equation (1) is equal to or less than a limit value (for example, 0.5), the sensitivity is not calculated, and is described in the operation manual with the adjustment amount being constant. The amount of adjustment is as follows.

(I) When the comfort level is "hot".
・ If the air conditioner is cooling or stopped, the cooling capacity is increased.
・ If the air conditioner is heating, it will reduce the heating capacity.

(Ii) The comfort level has shifted to the “cold” direction.
・ If the air conditioner is cooling, it will reduce the cooling capacity.
・ If the air conditioner is heating or stopped, increase the heating capacity.
(7) Simulation Function of the Embodiment of the Present Invention (g) Details of the simulation will be described individually with reference to FIG. There are several possible roles for this function, but here we describe how to deal with operations that deviate from the actual operating conditions.

  As an example of operation that deviates from the actual operating conditions, when operating with a smaller number of packaged air conditioners than usual due to failure or inspection, air conditioner operation is significantly deterred at specific times due to power saving requests, etc. Describe the case.

  Incorporates operating conditions such as temperature 28-1,28-2,28-3, ... 28-n and packaged air conditioners 29-1,29-2,29-3 ... 29-m Based on these data, the method of covering the air conditioning load is simulated by inputting the operable number, shared area, air conditioning load transition, and the like. Specifically, it is simulated how the packaged air conditioner that can be operated is operated with respect to the air conditioning load to be covered in each time zone (for example, in units of one hour). The capacity of the packaged air conditioner is obtained from the machine specifications 3. Considering that the air conditioning capacity is less than normal, a correction pattern 57-r is created for the basic pattern 57-o of the air conditioning capacity pattern 56, and the operation schedule 58 according to the number of units that can be operated is taken into account, including the advance of the start time. The management standard 21 is changed 59-1 at the start time 25-1, 559-2 at the operating unit 26-3, and 59-3 at the outside air temperature determination time 27-1.

  Next, the contents of simulation will be described with reference to FIG. 6B when the operation is performed with fewer air conditioners than usual or when the air conditioner operation is suppressed for a certain period of time by a power saving instruction. The correction pattern 57-r obtained as a result of setting the simulation conditions is obtained for the air conditioner operation basic pattern 57-o.

In Fig. 6 (B), the number of operating air conditioners in the lower left is reduced. Two cases will be described: a case where the driving ability is suppressed and a case where the capacity is greatly reduced due to a power saving request in the lower right. (I) Reduction in the number of operating air conditioners Since the number of operating air conditioners with respect to the air conditioning load is insufficient, the correction pattern 57-r is dealt with by adjusting the operating time of the air conditioner. The operating time is increased by raising the start time and lowering the stop time. However, considering that the load on air conditioning is the same as before and that the air conditioning capacity obtained by early morning operation can only be used for the air conditioning load that is generated at that time, air conditioning is in a time zone when air conditioning demand increases. The target temperature cannot be achieved due to insufficient capacity.

The temperature estimated from the air conditioning load at this time causes the temperature to rise or fall due to the load that cannot be covered by the air conditioning function. In order to make it possible for a person operating this ascent and descent to know, the lack of air conditioning capacity in each time zone (for example, every hour) is obtained and displayed.
(Ii) Significant reduction during a certain time period In response to power-saving measures, etc., there may be a case where the operation number (air conditioning capacity) of the air conditioner is significantly suppressed during a certain time period. In this case as well, the correction pattern 57-r has insufficient air conditioning function throughout the day with respect to the air conditioning demand. The operation of accumulating the integrated value of the air conditioning capacity to a predetermined value is performed.

  However, since the air conditioning load is generally covered at the time of occurrence, the air conditioning capacity obtained by the advancement is preserved by cooling the room air (or keeping it warm). The peak of demand for goods cannot be covered. The air conditioning capacity that is insufficient in the peak demand period and the air conditioner operation suppression time period is obtained, and based on this, the deviation width from the target temperature is obtained and described in the operation manual. The operator can take measures such as alerting the user based on this content.

The temperature divergence width is obtained using an air diagram from the insufficient air conditioning capacity and the volume of the air conditioning target space.
(8) According to the present embodiment, the following effects can be expected in addition to the general effects.
(I) Since maintenance management of the “Management Standard” stipulated by the Energy Conservation Law is possible in response to changes in on-site conditions, there is a possibility that an obligation to make an effort for improvement of 1% of the energy consumption basic unit, which is the duty of effort, can be realized every year Increasing, it can contribute not only to legal compliance but also to prevention of global warming.
(Ii) It is easy to balance comfort and energy saving because the feeling of users such as air conditioning can be reflected in the “management standard”. Furthermore, it is possible to operate the facility with an emphasis on energy saving after attaching the consent of the user in advance, and it is possible to respond quickly when it is necessary to further strengthen the energy saving due to social demands.
(Iii) Since maintenance management of the “management standard” is possible without the assistance of an expert, the cost of energy saving management can be reduced.
(Iv) For maintenance management of the “Management Standard”, the equipment specifications and operating conditions are referred to and the information is used. Therefore, when setting a new “Management Standard” for similar equipment, Can be easily used.
(V) The operational sensitivity, such as how the various operating variables (in this example, the number of packaged air conditioners and the output of each unit) described in “Management Standard” affect the air conditioning results and energy saving results. Since it is possible to grasp, when a facility is newly established, it is possible to introduce a facility having a higher degree of conformity to the purpose.
(Vi) Even when air conditioning cannot fully fulfill its purpose due to factors that cannot be controlled, such as external requests, it is possible to quantitatively grasp the shortage and perform appropriate equipment operation.

  As another embodiment of the present invention, the “maintenance method of production line operation manual” will be described below.

  As an object of the present embodiment, a processing / assembly process for manufacturing the product A will be taken up. The outline is shown in FIG. The processing / assembly process includes a molding shop 60, a parts assembly shop 61, a product assembly shop 62, and an inspection shop 63, and is equipped with a device for measuring the time when products or parts have passed through each shop entrance and exit. . 65-1 (inlet) and 65-2 (exit) for the molding shop 60, 66-1 (inlet) and 66-2 (exit) for the parts assembly shop 61, and 67 for the product assembly shop 62 -1 (inlet) and 67-2 (exit), and for the inspection shop 63, 68-1 (inlet) and 68-2 (exit), respectively. Also, for the sake of simplicity, each shop has only a space to store one or less products or parts. (Each shop will contain only products or parts that are being processed and assembled.) The difference in time required for each process is adjusted by a buffer provided between the processes.

  There is a product A manufacturing manual 75 for operating the entire system, and a molding shop operation manual 70, a parts assembly shop operation manual 71, a product assembly shop manual 72, and an inspection shop manual 73 are arranged below it. As shown in FIG. 7, the mutual relationship between the shops is that molding and parts assembly are performed in parallel, and then assembly and inspection are performed.

  In the present embodiment, the content of the operation manual 70 of the molding shop 60 is automatically updated as the operation progresses. In this example, when a new product is introduced into the production line, the process design is performed with a large expectation of the work time of each process in the initial stage, but the work time is shortened as the proficiency level of the worker increases. Is assumed. IE (Industrial Engineering) methods such as process analysis and work analysis are used for process design, but in this specification, the explanation of the IE and the details of the IE are not essentially related, so the explanation of IE is not Omitted.

  With reference to FIG. 8, information related to the update of the molding shop operation manual 70 will be described. The contents of the molding shop operation manual 70 are as shown in Table 76. In Table 76, in the initial process design, the work contents 77-3 are defined for each process 77-2 of process numbers 60-1, 60-2, 60-3,... 60-n. The working time 77-4 required for the work is determined as aa, bb, cc, dd,... Nn for each process.

  On the other hand, in the actual operation, for each product to be produced, the products to be input to the molding shop 60 are numbered 0001, 0002,..., And the time for the products to pass through the molding shop, UU0001, UU0002, UU0003, ... are measured. The molding shop passage time is calculated as follows.

UU (v) = TT (v) -SS (v) v = 0001,0002,0003, ...
In addition, in order to reflect the operator's opinion regarding the work time in the operation manual, each worker in the molding shop self-reports the work surplus time and obtains the average XX. Measures such as giving incentives after setting certain limits on the work surplus time.

  The update of the molding shop operation manual will be described with reference to FIG. The difference (aa-UU0001, bb-UU0002, cc-UU0003,...) Between the process passing time 77-4 (working time) of each product and the initially set working time 76-4 is obtained.

  Using this difference, an average 78 of worker self-report margin time, and a parameter 81 that is divided into deviations for each process, the work times aa, bb, Correct cc, ... nn. By making this correction multiple times as the proficiency level improves, the working time of each process converges to a value that can increase the maximum production efficiency under various constraints such as work personnel and equipment. The contents of parameters divided into deviations for each process and the method for correcting the work time 71-4 of each process will be described with reference to FIG.

In FIG. 10, the working time of each process described in the molding process operation manual is corrected by the following procedure.
(I) First, an operation result value margin time calculation 90 in the molding process is performed. In the molding process, the number of products created until the start of the modification of the working time is P, and an average uuAve of molding shop working time results (UU0001, UU0002... UUP) of these products is obtained. The process times described in the operation manual of the molding shop are summed up to determine the process time for each product in the molding shop. Find the time difference uuDev between these two types.
(Ii) Next, adjustment 91 with the self-report margin time XX of the worker is performed. Let S be the molding process work time reduction width,
If uuDev ≧ XX, S = XX × 0.5
If uuDev <XX, S = (uuDev + XX) x 0.5
And That is, if the self-report margin time XX is less than or equal to the calculated deviation uuDev, 50% of the self-report value is taken as the shortening range, and if XX is greater than uuDev, the average of both is taken.

In this way, adjustment is made so that shortening the process time does not place an excessive burden on the worker.
(I) When the shortening time S in the whole molding shop is obtained, this is allocated as the shortening time of each process by the following. A shortened time ratio table 81 for each process is prepared in advance. The shortening time ratio table 81 defines ratios (% display) for assigning shortening times to the respective steps 60-1, 60-2,... 60-n of the molding shop. Some process work contents cannot be shortened or have many margins for shortening, and are determined in advance in consideration of these characteristics. For example, since the press compression of 60-4 is a numerical value defined by the machine performance, the shortening ratio is almost zero. In addition, the material set 60-2 and the alignment are processes that can be expected to shorten a lot of time with learning of work, and a large ratio can be set.
(Ii) By subtracting the distribution ratio obtained from each process shortened time ratio table 81 from the preset time aa, bb, cc,... Then, the update operation time aa (1), bb (1), cc (1),... Nn (1) of each process is obtained, and the molding process operation manual is updated. In addition, the numerical value attached | subjected to each update operation time shows how many times of update.
(Iii) Assuming that this work time update is performed a plurality of times (R times) as the work proficiency level increases, a plurality of sets (R sets) of each process shortened time ratio table 81 are prepared. The value of this ratio is determined in consideration of the characteristics of the process constituting the molding shop, as in 4.

  In this way, the work time of each process described in the operation manual can be updated according to the work proficiency level, and the manual can be maintained.

The effects of this embodiment are as follows.
(Iv) Since the working time described in the operation manual is updated according to the level of proficiency of the worker, production with optimized capabilities of both the equipment and the worker can be realized over a long period of time. Can be expected to maximize.
(V) Since the work time is updated to reflect the self-declaration of the worker, the worker's moral improvement can be expected.
(Vi) Since the operator's self-report can be calibrated to the actual results, excessive updating can be avoided. In addition, it is possible to objectively evaluate the work time of the process that the worker is in charge of, and to be a motivation that leads to a real improvement.

    1: Initial setting of operation manual in conventional technology 2: Update of operation manual in conventional technology during operation of equipment / device, 3: Equipment specifications, 4: Operation plan, 5: Manual creation standard, 6: Existing similar manual, 7: Knowledge of designers / experts, 8: Equipment / equipment operation manual, 8EL: Expanded view of equipment / equipment operation manual, 8v: Updated equipment / equipment operation manual, 9: Target equipment / equipment, 10: Equipment / equipment in conventional technology Feedback to the operation manual from the device, 11: Initial setting of the operation manual in the present invention, 12: Dynamic maintenance management of the operation manual in the present invention, 13: Product / service user, 14: Update of the operation manual based on simulation results, 15: Feedback to the operation manual from users of products and services, 16: Update of the operation manual by measuring and monitoring the operation status, 17: Luck Manual description item example (1), 18: Operation manual description item example (2), 19: Operation manual description item example (3), 21: Management standard description example, 23: Package air conditioner specifications, 24: Store operation plan, 25: Management standard description example (contents), 26: Management standard description example (management standards), 27: Management standard description example (remarks), 28: Store air temperature, 29: Store package air conditioner, 30: Outside air temperature, 31 : Customer visit, 32: Customer questionnaire, 33: Employee diary, 41: Measured temperature statistical processing, 42: Package air conditioner operation pattern optimization, 43: Package air conditioner operation pattern diagram, 44: Air conditioner capacity pattern reflecting results, 45: Conversion of air conditioning capacity to reflect the actual number of equipment and capacity, 46: Update of management standards based on measurement results, 47: Calculation of air conditioning functional power required for adjustment, 48-a: Air conditioner operation pattern before change, 48-b: Air conditioner operation pattern after change, 49-1a-d : Air-conditioner accumulation capacity before change, 49-2a-d: Air-conditioner accumulation capacity after change, 51: Numerical value of user feedback (comfort level), 51d: User comfort level list, 51i: User comfort level input, 52: Statistical processing of user feedback, 53: Adjustment of management standard description items based on user feel, 53d: Comfort sensitivity list for air conditioning capability, 54: Management standard update based on user feel, 55: Driving pattern setting based on simulation results 56: Air conditioning capacity reflecting simulation results, 57: Air conditioning capacity patterns reflecting simulation results, 57o: Basic air conditioner operation pattern, 57r: Air conditioner operation correction pattern, 58: Number and capacity of air conditioning capacity reflecting simulation results 59: Management standard update by simulation results, 60: Molding shop, 61: Parts assembly shop, 62: Product assembly shop, 63: Inspection shop , 65: molding shop time measurement, 66: parts assembly shop time measurement, 67: product assembly shop time measurement, 68: inspection shop time measurement, 70: molding shop operation manual, 71: parts assembly shop operation manual, 72: product assembly Shop operation manual, 73: Inspection shop operation manual, 75: Product A manufacturing manual, 76: Items described in the molding shop operation manual, 77: Mold shop manufacturing performance table, 78: Worker declaration allowance time, 80: Mold shop operation time Change processing, 81: Reduction time ratio table, 82: Operation manual operation time before update acquisition, 83: Product manufacturing actual time acquisition, 84: Worker spare time acquisition, 85: Each process operation time update writing, 90 : Calculation of molding shop performance margin time, 91: Adjustment with worker margin time, 92: Each process allocation of adjusted time.

Claims (4)

An operation manual correction method for an operation manual correction device that corrects the operation manual according to the operation of the device,
The operation manual correction device is:
A specification step for specifying an item to be corrected according to the operation of the device in the operation manual;
A collecting step for collecting information on the operation of the device;
A correction step of obtaining a degree of correlation between information from a user of the device or a user who enjoys a service by the device and the capability of the device and correcting the item based on the degree of correlation is performed. Operation manual correction method. In the operation manual correction method according to claim 1,
In the specifying step, the operation manual correction device further specifies a target value related to the operation of the device,
In the correction step, the operation manual correction device calculates a deviation of the collected information from the target value based on the target value, and corrects the operation manual based on the deviation. In the operation manual correction method according to claim 1 or 2,
In the correction step, the operation manual correction device corrects the item by executing a simulation based on the collected information and information on specifications relating to the device. An operation manual correction device that corrects the operation manual according to the operation of the device,
An operation manual creation unit that creates an initial operation manual by specifying items to be modified according to the operation of the device;
An interface for collecting information on the operation of the device;
An operation manual correction apparatus characterized by obtaining a correlation between information from a user of the device or a user who enjoys a service by the device and the capability of the device, and correcting the item based on the correlation.

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