JP6553720B2 - Operation optimization support system and operation optimization support method - Google Patents

Description

  The present invention relates to an operation optimization support system and an operation optimization support method, and is suitably applied to an operation optimization support system and an operation optimization support method for supporting the machine operation optimization when detecting a failure sign of a machine. is there.

  Conventionally, based on internal information of a target device, it is determined whether the target device is in a state showing a sign of failure (a failure sign state), and a determination result is notified. For example, in Patent Document 1, it is determined whether or not a printer is in a failure sign state based on internal information of the printer, and a failure risk for determining the magnitude of the printer failure risk after determining that the printer is in a failure sign state A determination process is performed, and the determination result is notified. Thereby, a maintenance contractor, a user, and the like who receive the notification can grasp the degree of urgency of maintenance at that time.

JP 2010-91840 A

  However, in Patent Document 1 described above, since differences due to the operation of the machine before and after failure sign detection are not taken into consideration, it is possible to make a decision on maintenance availability based on the size of the failure risk. There was a problem that it was not possible to make decisions regarding changes in production conditions and operating conditions.

  The present invention has been made in consideration of the above points, and provides an operation optimization support system and operation optimization capable of presenting measures for failure signs detected based on production and operation plans and machine operation risks. It is intended to propose a support method.

  In order to solve such a problem, in the present invention, a machine, a production / operation management apparatus that manages production / operation of the machine, a production / operation planning apparatus that plans production / operation of the machine, A maintenance management device for managing an operation state and an operation risk, wherein the maintenance management device detects a failure sign of the machine, and the production and operation management device manages the production and operation planning device An operation optimization support system is provided, characterized in that a countermeasure plan for failure signs detected by the maintenance management device is created using the operation plan and operation risks managed by the maintenance management device. .

  In order to solve such a problem, in the present invention, a machine, a production / operation management apparatus that manages production / operation of the machine, a production / operation planning apparatus that plans production / operation of the machine, A method for supporting operation optimization in an operation optimization support system, comprising: a maintenance management device for managing an operation state and an operation risk, wherein the maintenance management device detects a failure sign of the machine; The operation management device prepares a countermeasure plan for the failure sign detected by the maintenance management device using the production / operation plan managed by the production / operation planning device and the operation risk managed by the maintenance management device. The operation optimization support method characterized by including a step.

  ADVANTAGE OF THE INVENTION According to this invention, the countermeasure against the failure sign detected based on the production / operation plan and the machine operation risk can be presented, and the failure risk of the target device can be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows the structural example of the operation optimization assistance system concerning the 1st Embodiment of this invention. It is a figure which illustrates schematic structure of the production and operation management apparatus concerning the embodiment. It is a figure which illustrates schematic structure of the production / operation plan apparatus concerning the embodiment. It is a figure which illustrates schematic structure of the maintenance management apparatus concerning the embodiment. It is a figure which shows the structural example of the production and operation condition management table concerning the embodiment. It is a figure which shows the structural example of the countermeasure candidate management table concerning the embodiment. It is a figure which shows the structural example of the production / operation capability management table concerning the embodiment. It is a figure which shows the structural example of the production / operation plan management table concerning the embodiment. It is a figure which shows the structural example of the time degradation risk management table concerning the embodiment. It is a figure which shows the structural example of the failure sign risk management table concerning the embodiment. It is a figure which shows the structural example of the operation risk threshold value management table concerning the embodiment. It is a figure which shows the structural example of the operation | use risk management table concerning the embodiment. It is a flow figure showing the example of a processing procedure of the measures proposal presentation method concerning the embodiment. It is a flow figure showing the processing procedure of failure sign diagnosis concerning the embodiment. It is a flowchart which shows the process procedure of the operation | movement risk update concerning the embodiment. It is a flowchart which shows the processing procedure of the countermeasure plan development concerning the embodiment. It is a flow figure showing the processing procedure of operation risk calculation concerning the embodiment. It is a figure which shows the example of presentation of the countermeasure plan concerning the embodiment. It is a figure which illustrates schematic structure of the quality assurance apparatus concerning the 2nd Embodiment of this invention. It is a figure which shows the structural example of the FMEA management table concerning the embodiment. It is a figure which shows the example of a structure of the symptom corresponding | compatible management table concerning the embodiment. It is a flowchart which shows the process sequence of FMEA item display concerning the embodiment. It is a figure which shows the example of presentation of the countermeasure plan concerning the embodiment. It is a figure which illustrates schematic structure of the production and operation management apparatus concerning the 3rd Embodiment of this invention. It is a figure which shows the structural example of the strategy management table concerning the embodiment. It is a figure which shows the example of presentation of the countermeasure plan concerning the embodiment.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

(1) First Embodiment (1-1) Configuration of Operation Optimization Support System FIG. 1 is a diagram illustrating a configuration example of an operation optimization support system according to the present embodiment. The operation optimization support system includes machines E001, E002 and E003 that execute production and operation, a production and operation management device A001 that manages production and operation of the machine, and a production and operation planning device that plans production and operation of the machine. It consists of A002, maintenance management device A003 which manages the operation state of the machine, and quality assurance device A004 which manages the influence at the time of machine failure, and these devices mutually transmit and receive information via network N001. it can. Incidentally, the quality assurance system A00 4 will be described in detail in the second embodiment.

  In the present embodiment, the maintenance management device A 003 detects a failure sign of the machine E 001. Then, the production and operation management apparatus A 001 prepares a countermeasure proposal for a failure sign using the production and operation plan managed by the production and operation planning apparatus A 002 and the machine operation risk managed by the maintenance management apparatus A 003 to the user. Present.

  Next, configurations of respective devices constituting the operation optimization support system according to the present embodiment will be described.

  FIG. 2 is a diagram illustrating a schematic configuration of the production / operation management device A001. As shown in FIG. 2, the production / operation management apparatus A001 includes a CPU 101, a memory 102, a storage device 103, a user interface 104, a communication interface 105, a production / operation condition management unit 111, and a countermeasure candidate management unit. 112, a countermeasure plan creation unit 113, and a countermeasure execution unit 114, which are designed to be able to transmit and receive each other via the internal bus 100.

  First, general-purpose components in the production / operation management apparatus A001 will be described.

  The CPU 101 is a central processing unit that performs various numerical calculations, information processing, device control, and the like. The memory 102 is a semiconductor storage device such as a RAM or a ROM that can be read and written directly by the CPU 101. The storage device 103 is a hard disk, magnetic tape, flash memory or the like that stores data and programs in a computer.

  The user interface 104 is a device such as a display, a mouse, or a keyboard for outputting a processing result to the user and receiving a user instruction and reflecting it on each component of the production / operation management apparatus A001.

  The communication interface 105 is a device for controlling transmission / reception of data via the network N001 of each component of the production / operation management apparatus A001. The communication interface 105 performs authentication processing with the other party to establish a communication path, and controls such as disconnecting the communication path after completion of the process or when there is no response from the other party even after a predetermined time has elapsed. I do.

  Next, components unique to the present embodiment in the production and operation management apparatus A001 will be described.

  The production / operation condition management unit 111 is a device that registers the production / operation conditions stored in the memory 102 or the storage device 103 in the production / operation condition management table T130 and performs processing such as updating. Details of the production and operation condition management table T130 will be described later.

  The countermeasure candidate management unit 112 is an apparatus that registers countermeasure candidates stored in the memory 102 or the storage device 103 in the countermeasure candidate management table T140 and performs processing such as updating. Details of the countermeasure candidate management table T140 will be described later.

  The countermeasure plan creation unit 113 includes a production / operation condition (obtained from the production / operation condition management unit 111), a countermeasure candidate (obtained from the countermeasure candidate management unit 112), and a production stored in the memory 102 or the storage device 103. A device that creates a countermeasure plan using the operation plan (obtained from the production and operation management device A 001) and the machine operation risk (obtained from the maintenance management device A 003), and stores it in the memory 102 or the storage device 103.

  The measure execution unit 114 is a device that executes a measure selected from a measure plan (obtained from the measure plan creation unit 113) stored in the memory 102 or the storage device 103.

  In addition, regarding the production / operation condition management unit 111, the countermeasure candidate management unit 112, the countermeasure plan creation unit 113, and the countermeasure execution unit 114, each device may execute processing alone or each device. May include only a program, and the CPU 101 may load the program into the memory 102 and execute the program.

  FIG. 3 is a diagram illustrating a schematic configuration of the production and operation planning device A002. As shown in FIG. 3, the production and operation planning device A 002 includes a CPU 201, a memory 202, a storage device 203, a user interface 204, a communication interface 205, a production and operation capacity management unit 211, and a production and operation plan. A management unit 212 and a production / operation plan creation unit 213 are provided, and are designed to be able to transmit and receive each other via the internal bus 200.

  About CPU201 which is a general-purpose component in production and operation plan device A002, memory 202, storage device 203, user interface 204, and communication interface 205, CPU101 of production and operation control device A001 shown in FIG. Since the memory 102, the storage device 103, the user interface 104, and the communication interface 105 have the same functions, detailed description will be omitted.

  Next, components unique to the present embodiment in the production and operation planning device A 002 will be described.

  The production / operation capability management unit 211 is a device that registers the production / operation capability stored in the memory 202 or the storage device 203 in the production / operation capability management table T230 and performs processing such as updating. Details of the production and operation capacity management table T230 will be described later.

  The production / operation plan management unit 212 is a device that registers a production / operation plan stored in the memory 202 or the storage device 203 in the production / operation plan management table T240 and performs processing such as updating. The details of the production and operation plan management table T240 will be described later.

  The production and operation plan creation unit 213 is configured from the production and operation conditions (obtained from the production and operation management apparatus A 001) and the production and operation capacity (from the production and operation capacity management unit 211) stored in the memory 202 or the storage device 203. Acquisition) and a production / operation plan (obtained from the production / operation plan management unit 212), a production / operation plan is created and stored in the memory 202 or the storage device 203.

  As for the production / operation capacity management unit 211, the production / operation plan management unit 212, and the production / operation plan creation unit 213, each device may execute processing alone, or each device may be a program. The CPU 201 may load the program into the memory 202 and execute the program.

  FIG. 4 is a diagram illustrating a schematic configuration of the maintenance management apparatus A003. As illustrated, the maintenance management apparatus A 003 includes a CPU 301, a memory 302, a storage device 303, a user interface 304, a communication interface 305, an operation risk constant management unit 311, an operation risk management unit 312, and an operation risk calculation. A part 313 and a failure sign detection part 314 are provided, and they are designed to be mutually transmitted / received via the internal bus 300.

  About CPU301 which is a general-purpose component in maintenance management apparatus A003, memory 302, storage device 303, user interface 304, and communication interface 305, CPU101 of production and operation management apparatus A001 shown in FIG. Since the memory 102, the storage device 103, the user interface 104, and the communication interface 105 have the same functions, detailed description will be omitted.

  Next, components unique to the present embodiment in the maintenance management apparatus A 003 will be described.

  The operation risk constant management unit 311 stores operation risk constants such as aging deterioration risk, failure sign risk, risk threshold value and the like stored in the memory 302 or the storage device 303, the deterioration risk management table T330, failure sign risk management table T340. The operation risk threshold management table T 350 is an apparatus that registers an operation risk constant, such as the operation risk threshold management table T 350, in a table that manages the update risk. Details of the temporal deterioration risk management table T330, the failure predictor risk management table T340, and the operation risk threshold management table T350 will be described later.

  The operation risk management unit 312 is a device that registers the operation risk stored in the memory 302 or the storage device 303 in the operation risk management table T360 and performs processing such as updating. Details of the operation risk management table T360 will be described later.

  The operation risk calculation unit 313 is a production / operation plan (obtained from the production / operation management device A001 or the production / operation planning device A002) stored in the memory 302 or the storage device 303, and a deterioration risk over time, a failure prediction risk This is a device that calculates an operation risk using an operation risk constant such as a maintenance guideline risk and stores it in the memory 302 or the storage device 303.

  The failure sign detection unit 314 is a device that stores failure sign information (created by the failure sign detection unit 314 or acquired from the machine E 001) in the memory 302 or the storage device 303. Note that each of the operation risk constant management unit 311, the operation risk management unit 312, the operation risk calculation unit 313, and the failure sign detection unit 314 may execute processing alone, or the respective devices may be performed. May include only a program, and the CPU 301 may load the program into the memory 302 and execute the program.

  Next, the data structure of the table used by the operation optimization support system will be described.

  FIG. 5 is a diagram illustrating a configuration example of the production / operation condition management table T130. The production / operation condition management table T130 is a list of production / operation conditions under which the current machine managed by the production / operation management apparatus A001 operates as described in the explanation of FIG.

  As shown in FIG. 5, the production / operation condition management table T130 includes a machine column 131 for storing machine identifiers, temperature, pressure, speed, acceleration, deceleration (brake), route, and vehicle currently selected by the machine. It includes a production / operation condition column 132 for storing an identifier of production / operation conditions such as a configuration, and a product condition column 133 for storing an identifier of a product currently produced by the machine.

  In the example of FIG. 5, it can be seen that the machine E001 currently produces the product G001 under the production / operation condition B111, and the machine E002 produces the product G002 under the production / operation condition B221. Here, the value of the production / operation condition column and the product column of the machine E003 being “−” indicates that the machine E003 is not currently operating.

  FIG. 6 is a diagram showing a configuration example of the countermeasure candidate management table T140. The countermeasure candidate management table T140 is a list of candidate countermeasures that can be implemented at the time of failure sign detection managed by the production / operation management apparatus A001, as described in the explanation of FIG.

  As shown in FIG. 6, the countermeasure candidate management table T140 includes a countermeasure candidate column 141 for storing countermeasure contents, an additional number of days column 142 for storing time required for implementing countermeasures, and an additional storage for storing expenses required for implementing countermeasures. The cost column 143 is configured.

In the example of FIG. 6, if the countermeasure content is "as is", the additional time is "0" and the additional cost is "0", and if the countermeasure content is "part replacement ", the additional time is "10" and the additional cost is " It can be seen that it is 100 ". Here, the additional time column 142 and the additional cost column 143 may be a mathematical expression using other information such as a machine, failure sign information, and a date as a variable, an identifier representing an acquisition destination, or the like.

  FIG. 7 is a diagram showing a configuration example of the production and operation capacity management table T230. The production / operation capacity management table T230 is a list of the production / operation capacity of the machine managed by the production / operation planning apparatus A002 as described in the explanation of FIG.

  As shown in FIG. 7, the production / operation capacity management table T230 includes a machine column 231 for storing machine identifiers, temperature, pressure, speed, acceleration, deceleration (brake), route, vehicle configuration, etc. selected by the machine. A production / operation condition column 232 for storing an identifier of production / operation conditions, a product column 233 for storing an identifier of a product engaged in the machine, a capability column 234 for storing a product production capacity such as a speed, and the like.

  In the example of FIG. 7, it is understood that the machine E001 produces the product G001 at the production / operation condition B111 with the ability "10" and the machine E002 produces the product G001 at the production / operation condition B211 with the ability "8". It can be seen that with regard to production the capacity of the machine E001 is high. Further, since the machine E001 produces the product G001 with the capacity “6” under the production / operation condition B112, it can be seen that the capacity changes by changing the production / operation conditions. Further, since the machine E001 produces the product G002 with the capacity “8” under the production / operation condition B121, it can be seen that another product can be produced by changing the production / operation conditions. Here, the value in the capability column 234 may be a mathematical expression using other information such as production / operation conditions and operation time as a variable, an identifier representing an acquisition destination, or the like.

  FIG. 8 is a diagram showing a configuration example of the production and operation plan management table T240. The production / operation plan management table T240 is a list of production / operation plans for each product managed by the production / operation plan apparatus A002 as described in the explanation of FIG.

  As shown in FIG. 8, the production / operation plan management table T240 includes a product column 241 for storing product identifiers, a remaining amount column 242 for storing the remaining production amount up to the product production target, It comprises the remaining time column 243 etc. which stores the remaining time.

  In the example of FIG. 8, it is understood that the product G001 should produce the remaining “80” in the remaining “15” time, and the product G002 should produce the remaining “150” in the remaining “30” time. Here, the remaining amount column 242 and the remaining time column 243 may be mathematical expressions using other information such as market information and date as variables, identifiers representing acquisition sources, and the like.

FIG. 9 is a diagram illustrating a configuration example of the temporal deterioration risk management table T330. Time degradation risk management table T330, as mentioned in the description of FIG. 4, a list of over time degradation risk of the machine to manage the maintenance management apparatus A003.

  As shown in FIG. 9, the temporal deterioration risk management table T330 includes a machine column 331 storing machine identifiers, and production of temperature, pressure, speed, acceleration, deceleration (brake), route, vehicle configuration, etc. selected by the machine. A production / operation condition column 332 for storing operation condition identifiers, a component column 333 for storing identifiers of machine maintenance target parts, and a coefficient column 334 for storing an increase coefficient of operation risk over time.

In the example of FIG. 9, machine E001 is running an increased risk coefficient of parts P0 1 1 is "15" in production and operation conditions B111, machine E002 is running an increased risk factor in the production and operation conditions B211 "10", the machine It can be seen that the operation risk increase of the machine E 001 is large. In addition, the machine E001 from that operation increased risk coefficient of parts P0 1 1 in the production and operation conditions B112 is "3", it can be seen that the operation increased risk is changed by changing the production and operation conditions. In addition, the machine E001 from that operation increased risk coefficient of parts P0 1 2 in production and operation conditions B121 is "10", it can be seen that the parts operation risk is increased by changing the production and operation conditions change. Here, the value in the coefficient column 334 may be a mathematical expression using other information such as production / operation conditions and operating time as a variable, an identifier representing an acquisition destination, or the like.

  FIG. 10 is a diagram showing a configuration example of the failure sign risk management table T340. The failure sign risk management table T340 is a list of machine failure sign risks managed by the maintenance management apparatus A003 as described in the description of FIG.

  As shown in FIG. 10, the failure sign risk management table T340 includes a failure sign column 341 for storing an identifier of a failure sign, a risk degree column 342 for storing an operation risk that increases upon detection of a failure sign, and the like.

  In the example of FIG. 10, it is understood that the operation risk increases by "1000" when the failure sign D001 is detected. Here, the value of the risk degree column 342 is an absolute value such as a constant value or infinity which does not depend on a formula that uses other information as a variable, such as operation risk at the time of detection or part identifier, or the operation risk at that time. It may be an identifier representing a value or an acquisition destination.

  FIG. 11 is a diagram showing a configuration example of the operation risk threshold value management table T350. The operation risk threshold value management table T350 is a list of operation risk threshold values of the machines managed by the maintenance management apparatus A003, as described in the explanation of FIG.

  As shown in FIG. 11, the operation risk threshold management table T350 includes a machine column 351 for storing machine identifiers, a parts column 352 for storing machine maintenance target parts identifiers, and an operation risk threshold value as an indication of maintenance. The threshold value column 353 is stored.

  In the example of FIG. 11, it can be seen that the threshold value of the operation risk of the part P011 of the machine E001 is "2000". Here, the value of the threshold column 353 may be an equation that uses other information such as operating time as a variable, or an identifier that represents an acquisition destination.

  FIG. 12 is a diagram illustrating a configuration example of the operation risk management table T360. The operation risk management table T360 is a list of current operation risks of the machines managed by the maintenance management apparatus A003 as described in the explanation of FIG.

  As shown in FIG. 12, the operation risk management table T360 includes a machine column 361 for storing machine identifiers, a parts column 362 for storing machine maintenance target parts identifiers, and a risk degree column for storing the present operation risks of parts. 363 or the like. In the example of FIG. 12, it can be seen that the current operation risk of the part P011 of the machine E001 is "935".

(1-2) Countermeasure plan presentation processing Next, details of the countermeasure plan presentation processing in the present embodiment will be described.

  FIG. 13 is a flowchart showing an example of a processing procedure of countermeasure proposal presentation processing in the present embodiment. Each step described below is realized by a program executed by each device constituting the operation optimization support system shown in FIG. These programs are composed of codes for performing various operations described below. This premise is the same for other processing procedures.

  As shown in FIG. 13, the failure sign detection unit 314 of the maintenance management apparatus A003 diagnoses a failure sign (S001). Specifically, the failure sign detection unit 314 detects a failure sign of a machine and stores information on the machine and the failure sign in the memory 302 or the storage device 303. Here, the maintenance sign device A003, the machine E001, or another device may be used to create the failure predictor information.

  With reference to FIG. 14, the failure sign diagnosis process in step S001 will be described. First, the machine E001 collects operation information (S011). Here, the operation information includes not only production and operation information such as operation time, parts used, production and operation conditions, but also machines and parts such as information indicating symptoms such as vibration, sound, and images and maintenance history. Information on the work of the

  Then, the machine E 001 transmits the operation information to the maintenance management device A 003 (S 012). Then, the failure sign detection unit 314 of the maintenance management device A003 receives the operation information via the communication interface 305 and stores it in the memory 302 or the storage device 303 (S013). Here, it is assumed that the stored operation information includes the machine “E001”, the part “P011”, the production / operation condition “B111”, and the elapsed time “1”.

  Next, the failure sign detection unit 314 of the maintenance management apparatus A003 diagnoses the failure sign using the operation information stored in the memory 302 or the storage device 303. Here, the diagnosis of the failure sign may be a diagnosis using current information such as threshold detection or a diagnosis using past information and current information such as abnormality detection using clustering.

  Then, the failure sign detection unit 314 of the maintenance management device A 003 determines the presence or absence of a failure sign (S014), and determines whether there is a failure sign (S015). Assuming that the failure sign D001 is detected in step S015, the failure sign detection unit 314 of the maintenance management apparatus A 003 stores the failure sign information in the memory 302 or the storage device 303 (S016). Here, it is assumed that the failure sign "D001" is included in the stored failure sign information.

  Returning to FIG. 13, the operation risk calculation unit 313 of the maintenance management apparatus A003 updates the operation risk (S002). Specifically, the operation risk calculation unit 313 calculates the current operation risk of the machine acquired from the operation risk management unit 312 based on the information of the machine stored in the memory 302 or the storage device 303, the memory 302 or the memory The new operation risk of the machine is calculated using the increase amount of the operation risk acquired from the operation risk constant management unit 311 based on the information of the failure sign stored in the device 303, and stored in the memory 302 or the storage device 303. To do. Then, the operation risk management unit 312 updates the operation risk management table T360 based on the new operation risk of the machine stored in the memory 302 or the storage device 303.

  With reference to FIG. 15, the operation risk update processing in step S002 will be described. First, the operation risk calculation unit 313 of the maintenance management apparatus A 003 acquires the current value of the operation risk from the operation risk management table T 360 via the operation risk management unit 312 (S 021). Here, based on the machine “E001”, the part “P011” and the production and operation condition “B111” stored in the memory 302 or the storage device 303, the current operation risk “935” of the machine (FIG. Record 364) is acquired.

  Next, the operation risk calculator 313 of the maintenance management device A 003 calculates an increase in the risk of deterioration over time using the deterioration risk management table T330 (S022). Here, based on the machine "E001", the part "P011" and the production / operation condition "B111" stored in the memory 302 or the storage device 303, the deterioration risk increasing coefficient over time "15" (the record in FIG. 335) is obtained, and the risk increase “15” of deterioration with time is calculated by multiplication with the elapsed time “1” stored in the memory 302 or the storage device 303.

  Then, the operation risk calculation unit 313 of the maintenance management apparatus A003 determines whether or not there is a failure sign (S023). Here, as failure sign information, there is an identifier “D001” of the failure sign.

  If it is determined in step S 023 that there is a failure sign, the operation risk calculation unit 313 of the maintenance management apparatus A 003 refers to the failure sign risk management table T 340 to calculate the risk increase of the failure sign (S 024). Here, based on the identifier "D001" of the failure sign stored in the memory 302 or the storage device 303, the risk increase "1000" (record 343 in FIG. 10) of the failure sign is acquired.

  Then, the operation risk calculation unit 313 of the maintenance management device A 003 calculates a new operation risk, and updates the operation risk management table T 360 through the operation risk management unit 312. Here, adding the risk increase “15” of deterioration over time and the risk increase “1000” of failure sign to the current operation risk “935” of the machine, the new operation risk “1950” is calculated to calculate the operation risk Update (S025).

  Returning to FIG. 13, next, the failure sign detection unit 314 of the maintenance management device A 003 sends the machine stored in the memory 302 or the storage device 303 to the production / operation management device A 001 via the communication interface 305 and the failure sign Is transmitted (S003). Then, the countermeasure plan creation unit 113 of the production / operation management apparatus A001 receives information on the machine and the failure sign via the communication interface 105 and stores the information in the memory 102 or the storage device 103.

  In the above, the failure sign detection unit 314 of the maintenance management device A 003 includes the machine “E001”, the part “P011”, the production and operation condition “B111”, and the failure sign “D001” stored in the memory 302 or the storage device 303. Assume that the data is transmitted to the production / operation management apparatus A001. Further, it is assumed that the countermeasure plan creating unit 113 of the production and operation management apparatus A 001 stores the information received from the maintenance management apparatus A 003 in the memory 102 or the storage device 103.

  Next, the countermeasure candidate management unit 112 of the production and operation management apparatus A 001 acquires countermeasure candidate information from the countermeasure candidate management table T 140 based on the information on the machine and the failure sign stored in the memory 102 or the storage device 103. Then, it is stored in the memory 102 or the storage device 103 (S004).

  In the above, the countermeasure candidate management unit 112 of the production / operation management apparatus A001 receives from the countermeasure candidate management unit 112 "as is", "condition change", "product change", "product" as the countermeasure candidate (column 141 in FIG. 6). Acquire “consignment”, “machine replacement”, “part replacement”, additional time for the countermeasure candidate (column 142 in FIG. 6), and additional cost for the countermeasure candidate (column 143 in FIG. 6) Is stored in the memory 102 or the storage device 103.

  Then, in order to calculate the plan of each countermeasure candidate included in the acquired information of the countermeasure candidate, the countermeasure plan creation unit 113 of the production / operation management device A 001 sends to the production / operation planning device A 002 via the communication interface 105 The information on each countermeasure candidate and the current production and operation conditions acquired from the production and operation condition management unit 111 are transmitted, and a request for planning of each countermeasure candidate is requested (S005).

  Then, the production / operation planning unit 213 of the production / operation planning apparatus A 002 receives the information of each countermeasure candidate and the current production / operation conditions via the communication interface 205, and stores the information in the memory 202 or the storage device 203. To do.

  In the present embodiment, the countermeasure plan creating unit 113 of the production and operation management apparatus A 001 is a machine “E 001”, a part “P 011” and a production and operation condition “B 111” stored in the memory 102 or the storage device 103. The combination of the countermeasure candidate (column 141 in FIG. 6), the additional time (column 142 in FIG. 6), the machine (column 131 in FIG. 5) acquired from the production / operation condition management unit 111, the production / operation condition (FIG. 5) It is assumed that the combination of the column 132) and the product (the column 133 in FIG. 5) is transmitted, and the planning of each countermeasure candidate is requested. In addition, it is assumed that the production / operation planning unit 213 of the production / operation planning apparatus A 002 stores the information received from the production / operation management apparatus A 001 in the memory 202 or the storage device 203.

  Next, the production / operation plan creation unit 213 of the production / operation planning apparatus A002 formulates a countermeasure plan (S006). Specifically, the production and operation plan creation unit 213 includes information on countermeasure candidates stored in the memory 202 or the storage device 203, current production and operation conditions stored in the memory 202 or the storage device 203, and production. -Based on the production and operation capacity acquired from the operation capacity management unit 211 and the production and operation plan acquired from the production and operation plan management unit 212, the plan of the countermeasure candidate is calculated and the feasible one is taken as a countermeasure plan Formulate.

  Then, the production / operation plan creation unit 213 transmits the formulated countermeasures to the production / operation management apparatus A001 via the communication interface 205. Then, the countermeasure plan creation unit 113 of the production / operation management apparatus A001 receives each countermeasure plan via the communication interface 105 and stores it in the memory 102 or the storage device 103.

  With reference to FIG. 16, the process for formulating a countermeasure plan in step S006 will be described. First, the production and operation plan creation unit 213 of the production and operation planning apparatus A 002 acquires one by one each of the countermeasure candidates stored in the memory 202 or the storage device 203 (S061). The following steps S062 to S064 are repeated until there are no countermeasure candidates.

  That is, the production and operation plan preparation unit 213 acquires the machine, conditions and capacity (S062), calculates the production time (S063), determines whether the calculated production time can be realized (S064), and can be realized If so, it is recorded as a countermeasure plan (S065).

  Here, it is assumed that the countermeasure candidate “as is” is acquired in step S061. In this case, in step S062, the production and operation plan creation unit 213 generates the current machine "E001" of the product "G001" stored in the memory 202 or the storage device 203, and the production and operation condition "B111" (FIG. 5). The production / operation capacity “10” (record 235 in FIG. 7) is acquired from the production / operation capacity management table T230 via the production / operation capacity management unit 211 based on the record 134).

Then, in step S063, based on the product "G001", the remaining production amount is "80" (record 244 in FIG. 8) from the production and operation plan management table T240 via the production and operation plan management unit 212. The necessary production time “8” is calculated by obtaining and dividing by the production / operation capacity “10” obtained in step S062.

  Then, in step S064, "0" (record 144 in FIG. 6), which is the additional time of the countermeasure candidate "as is", is added to calculate the achievement time "8" of the production target of the product G001. This is determined to be feasible because the remaining production time "15" (record 244 in FIG. 8) of the product G001 is equal to or less.

  If it is determined in step S064 that it is feasible, the countermeasure candidate "as is" is stored in the memory 202 or the storage device 203 as a countermeasure plan together with the production time "8" and the achievement time "8" in step S065.

  Next, it is assumed that the countermeasure candidate “condition change” is acquired in step S061. In this case, in step S062, the production and operation plan creation unit 213 uses the current machine "E001" of the product "G001" stored in the memory 202 or the storage device 203, and the production and operation conditions "B111" (FIG. 5). Based on the record 134), the production / operation capacity management unit 211, from the production / operation capacity management table T230, the other production / operation conditions “B112” that can produce the product “G001” with the machine “E001” The production / operation capability “6” (record 236 in FIG. 7) is acquired.

Then, in step S063, based on the product "G001", the remaining production amount is "80" (record 244 in FIG. 8) from the production and operation plan management table T240 via the production and operation plan management unit 212. The necessary production time “14” is calculated by obtaining and dividing by the production / operation capacity “6” obtained in step S062. Here, the time is calculated by rounding up the fractional part, but fraction processing may be performed by other methods.

  Then, in step S064, “1” (record 145 in FIG. 6) which is the additional time of the countermeasure candidate “condition change” is added to calculate the achievement time “15” of the production target of the product G001. This is determined to be feasible because the remaining production time "15" (record 244 in FIG. 8) of the product G001 is equal to or less.

  If it is determined in step S064 that it is feasible, then in step S065, the memory 202 as a countermeasure is proposed with the production / operation condition "B112", the production time "14", the achievement time "15", and the countermeasure candidate "condition change". Alternatively, it is stored in the storage device 203.

  Next, it is assumed that the countermeasure candidate “product change” is acquired in step S061. In this case, in step S062, the production and operation plan creation unit 213 uses the current machine "E001" of the product "G001" stored in the memory 202 or the storage device 203, and the production and operation conditions "B111" (FIG. 5). Production and operation based on the current machine “E 002” of the product “G 002” and the production and operation condition “B 221” (record 135 in FIG. 5) of the product “G 002” via the production and operation capacity management unit 211 From the capacity management table T230, the machine "E002" can replace the product to be produced with the machine "E001", the production and operation condition "B211", the production and operation capacity "8" (record 238 in FIG. 7), and the machine "E001" The production / operation condition “B121”, the product “G002”, and the production / operation capability “8” (record 237 in FIG. 7) are acquired.

Then, in step S063, based on the product "G001", the remaining production amount is "80" (record 244 in FIG. 8) from the production and operation plan management table T240 via the production and operation plan management unit 212. The necessary production time “10” is calculated by dividing by the production / operation capacity “8” of the product G001 obtained in step S062. Also, based on the product "G002", the remaining production amount "150" (record 24 5 in FIG. 8) is acquired from the production and operation plan management table T240 via the production and operation plan management unit 212, The necessary production time “19” is calculated by dividing by the production / operation capacity “8” of the product G002 acquired in step S062. Here, the time is calculated by rounding up the fractional part, but fraction processing may be performed by other methods.

  Then, in step S064, "1" (record 146 in FIG. 6), which is the additional time of the countermeasure candidate "product change", is added, and the achievement time "11" of the production target of product G001 and the product target of product G002 are achieved Time “20” is calculated. This is less than the remaining production time "15" (record 244 in FIG. 8) of the product G001, and is determined to be feasible because it is less than the remaining production time "30" (record 245 in FIG. 8) of the product G002.

  If it is determined in step S064 that it is feasible, then in step S065, the countermeasure candidate "product replacement" is product "G001", machine "E002", production / operation condition "B211", production time "10", achievement time Both “11”, product “G002”, machine “E001”, production / operation condition “B121”, production time “19”, achievement time “20” are stored in the memory 202 or the storage device 203 as a countermeasure plan.

  Next, it is assumed that the countermeasure candidate “product consignment” is acquired in step S061. In this case, in step S062, the production and operation plan creation unit 213 uses the current machine "E001" of the product "G001" stored in the memory 202 or the storage device 203, and the production and operation conditions "B111" (FIG. 5). Production and operation based on the current machine “E 002” of the product “G 002” and the production and operation condition “B 221” (record 135 in FIG. 5) of the product “G 002” via the production and operation capacity management unit 211 From the capability management table T230, the machine "E002" to which the product "G001" can be outsourced, the production / operation condition "B211", and the production / operation capacity "8" (record 238 in FIG. 7) are acquired. However, since the machine E002 produces both the product G001, the product G001, and the product G002, the production / operation capacity is assumed to be “4”, which is half. Here, the change in machine performance at the time of production of a plurality of products may be adjusted according to the ratio of products or time division.

Then, in step S063, based on the product "G001", the remaining production amount is "80" (record 244 in FIG. 8) from the production and operation plan management table T240 via the production and operation plan management unit 212. The necessary production time “20” is calculated by obtaining and dividing by the production / operation capacity “4” obtained in step S062.

  Then, in step S064, “1” (record 147 in FIG. 6), which is the additional time of the countermeasure candidate “product consignment” is added, and “21” is required as the time required to achieve the production target of product G001. calculate. Since this is longer than the remaining production time “15” of the product G 001 (record 244 in FIG. 8), it is determined that it can not be realized.

  Next, it is assumed that a countermeasure candidate “machine replacement” is acquired in step S061. In this case, in step S062, the production and operation plan creation unit 213 uses the current machine "E001" of the product "G001" stored in the memory 202 or the storage device 203, and the production and operation conditions "B111" (FIG. 5). Production / operation capacity management unit 211 via the production / operation capacity management unit 211 based on the record 134) of the machine, the machine “E003”, the production / operation condition “−”, and the product “−” (record 136 in FIG. 5) From the table T230, the machine "E003" that can be replaced with the machine "E001", the production / operation condition "B311", and the production / operation capacity "8" (record 239 in FIG. 7) are acquired.

Then, in step S063, based on the product "G001", the remaining production amount is "80" (record 244 in FIG. 8) from the production and operation plan management table T240 via the production and operation plan management unit 212. The necessary production time “10” is calculated by obtaining and dividing by the production / operation capacity “8” obtained in step S062.

  Then, in step S064, "3" (record 148 in FIG. 6), which is the additional time of the countermeasure candidate "machine replacement", is added, and "13" is set as the time required to achieve the production target of product G001. calculate. This is determined to be feasible because the remaining production time “15” (record 244 in FIG. 8) of the product G 001 is equal to or less.

  Then, in step S065, the countermeasure candidate "machine replacement" is stored in the memory 202 or the storage device 203 as a countermeasure plan together with the machine "E003", the production / operation condition "B311", the production time "10" and the achievement time "13". To do.

  Next, in step S061, it is assumed that the countermeasure candidate "part replacement" is acquired. In this case, in step S062, the production and operation plan creation unit 213 uses the current machine "E001" of the product "G001" stored in the memory 202 or the storage device 203, and the production and operation conditions "B111" (FIG. 5). The production / operation capability “10” (record 235 in FIG. 7) is acquired from the production / operation capability management table T230 via the production / operation capability management unit 211.

Then, in step S063, based on the product "G001", the remaining production amount is "80" (record 244 in FIG. 8) from the production and operation plan management table T240 via the production and operation plan management unit 212. The necessary production time “8” is calculated by obtaining and dividing by the production / operation capacity “10” obtained in step S062.

  Then, in step S 064, “10” (record 149 in FIG. 6) which is the additional time of the countermeasure candidate “part replacement” is added, and “18” is required as the time required to achieve the production target of product G 001 calculate. Since this is longer than the remaining production time “15” of the product G 001 (record 244 in FIG. 8), it is determined that it can not be realized.

  Here, the production of the product G001 as a candidate for countermeasures may be outsourced to other vendors, and distributed production may be performed by a plurality of machines.

  Referring back to FIG. 13, the countermeasure plan creating unit 113 of the production and operation management apparatus A 001 communicates to calculate the operation risk of each countermeasure candidate included in the information of the countermeasure candidate stored in the memory 102 or the storage device 103. The plan of each countermeasure candidate stored in the memory 102 or the storage device 103 is transmitted to the maintenance management device A 003 via the interface 105, and the operation risk calculation of each countermeasure candidate is requested (S007). Then, the operation risk calculator 313 of the maintenance management device A 003 receives the information of each countermeasure candidate and the plan thereof via the communication interface 305, and stores the information in the memory 302 or the storage device 303.

  Next, the operation risk calculation unit 313 of the maintenance management apparatus A003 calculates the operation risk of the countermeasure plan (S008). Specifically, the operation risk calculation unit 313 includes information on countermeasure candidates stored in the memory 302 or the storage device 303, a countermeasure plan stored in the memory 302 or the storage device 303, and the operation risk constant management unit 311. Based on the acquired operation risk constant and the current operation risk acquired from the operation risk management unit 312, the operation risk of the countermeasure plan is calculated.

  Subsequently, the operation risk calculation unit 313 transmits the calculated operation risks of the respective countermeasure plans to the production / operation management apparatus A 001 via the communication interface 305. Then, the countermeasure plan creating unit 113 of the production and operation management apparatus A 001 receives the operation risk of each countermeasure plan through the communication interface 105, and stores it in the memory 102 or the storage device 103.

  With reference to FIG. 17, the operation risk calculation process in step S008 will be described. First, the operation risk calculation unit 313 of the maintenance management apparatus A 003 acquires one by one each of the countermeasure plans stored in the memory 302 or the storage device 303 (S 081). The following steps S082 to S083 are repeated until there is no solution plan.

  That is, the operation risk calculation unit 313 calculates an increase in the risk of deterioration with time (S082), and records the operation risk (S083).

  In step S081, it is assumed that the countermeasure plan “as is” is acquired. In this case, based on the machine "E001" and the production / operation condition "B111" in step S082, the operation risk increase coefficient of the part P011 from the aging risk management table T330 via the operation risk constant management unit 311 By acquiring “15” (record 335 in FIG. 9) and multiplying it by the production time “8”, the risk increase “120” of deterioration with time is calculated.

  Then, in step S 083, this risk increase “120” is added to the current operation risk “1950” of the part P 011 calculated in step S 002 to calculate the operation risk “2070”, along with the countermeasure plan “as it is” It is stored in the memory 302 or the storage device 303.

Next, it is assumed that a countermeasure plan “condition change” is acquired in step S081. In this case, in step S082, based on the machine "E001" and the production and operation condition "B112", the operation risk increase coefficient of the part P011 from the aging risk management table T330 via the operation risk constant management unit 311 3 ”(record 33 6 in FIG. 9) is obtained and multiplied by the production time“ 14 ”to calculate the risk increase“ 42 ”of deterioration with time.

  Then, in step S 083, the risk increase “42” is added to the current operation risk “1950” of the part P 011 calculated in step S 002 to calculate the operation risk “1992”, and the countermeasure plan “condition change” And stored in the memory 302 or the storage device 303.

  Next, it is assumed that a countermeasure plan “product change” is acquired in step S081. In this case, in step S082, based on the machine "E001" and the production / operation condition "B121", the operation risk increase coefficient of the part P011 is calculated from the aging risk management table T330 through the operation risk constant management unit 311 can not get. In this case, it is assumed that the operation risk of the component P011 does not increase. Here, the operation risk may be calculated with a policy of increasing without using parts.

  Then, in step S 083, the current operation risk “1950” of the part P 011 is stored in the memory 302 or the storage device 303 together with the countermeasure plan “product change”.

  Next, it is assumed that a countermeasure plan “machine replacement” is acquired in step S081. In this case, in step S082, based on the machine "E001" and the production and operation conditions "-", the operation risk increase coefficient of the part P011 is calculated from the aging risk management table T330 through the operation risk constant management unit 311 can not get. In this case, it is assumed that the operation risk of the component P011 does not increase. Here, the operation risk may be calculated with a policy of increasing without operating the machine.

  Then, in step S 083, the current operation risk “1950” of the part P 011 is stored in the memory 302 or the storage device 303 together with the countermeasure plan “machine replacement”.

  Referring back to FIG. 13, in step S 009, the countermeasure plan creating unit 113 of the production and operation management apparatus A 001 receives the information on the failure sign and the countermeasure plan stored in the memory 102 or the storage device 103 via the user interface 104. Present to the user. Here, modification may be performed using a risk threshold value or the like that can be acquired from the operation risk constant management unit 311 of the maintenance management apparatus A 003.

  With reference to FIG. 18, the example of presentation of a countermeasure plan is demonstrated. The countermeasure plan is displayed in a list (display item C002 in FIG. 18) together with the detected failure sign information (display item C001 in FIG. 18). In the countermeasure plan, the time required for achieving the production target calculated in steps S 005 to S 008, and the operation risk when the target of the part P 011 of the machine E 001 which is the target of the detected failure sign is achieved are displayed. Further, the additional cost of the countermeasure plan (column 143 in FIG. 6) is also displayed.

  Further, since the operation risk threshold value of the part P011 of the machine E001 that can be acquired from the operation risk constant management unit 311 of the maintenance management apparatus A003 is "2000" (record 354 in FIG. 11), it is included in the operation risk of the countermeasure plan. If there is an excess, the background is colored (display item C003 in FIG. 18). In addition, if there is no change from the current operation risk among the operation risks of the countermeasure plan (the part P011 is not used), the characters are italicized (display item C004 in FIG. 18).

  Here, the user reorders the items (time, risk, cost) to be emphasized in the operation situation at that time (display items C 007, C 008, C 009 in FIG. 18), and selects a countermeasure plan (FIG. 18). When the display item C010) is instructed to execute the countermeasure (display item C011 in FIG. 18), the countermeasure execution unit 114 of the production / operation management apparatus A001 executes the selected countermeasure. At that time, it may only reflect the production and operation plan managed by the production and operation planning device A 002, or may automatically send an instruction to a machine, other systems such as a parts ordering system, a call system for maintenance personnel, etc. You may work with other companies' systems.

(1-3) Effects of the Present Embodiment According to the above embodiment, the production / operation management apparatus A001 that controls the production / operation of the machine E001 and the like, and the production / operation planning apparatus that plans the production / operation of the machine The operation optimization support system having A002 and the maintenance management device A003 that manages the operation state and operation risk of the machine, the maintenance management device A003 detects a failure sign of the machine, and the production / operation management device A001 Based on the production and operation plan managed by the production and operation planning device A 002 and the operation risk managed by the maintenance management device A 003, a countermeasure plan for the failure sign detected by the maintenance management device A 003 is prepared. In this way, when machine failure signs are detected, it is possible to support the user's decision-making in accordance with the items to be emphasized in the operation situation at that time in order to optimize the machine operation.

(2) Second Embodiment (2-1) Configuration of Operation Optimization Support System In the present embodiment, when the production / operation management apparatus A 001 presents a measure plan in the first embodiment. , FMEA (Failure Mode and Effects Analysis) information will be added. FMEA is an analysis method that analyzes failure modes of machines and their effects.

  With reference to FIG. 19, the structure of each apparatus which comprises an operation optimization assistance system is demonstrated. Here, the configurations of the production and operation management device A 001, the production and operation planning device A 002, and the maintenance management device A 003 are the same as in the first embodiment, and thus detailed description will be omitted.

  Below, the structure of quality assurance apparatus A004 peculiar to this Embodiment is demonstrated in detail. FIG. 19 is a diagram illustrating a schematic configuration of the quality assurance device A004. As shown in FIG. 19, the quality assurance apparatus A 004 includes a CPU 401, a memory 402, a storage device 403, a user interface 404, a communication interface 405, an FMEA management unit 411, and a predictive action management unit 412. Are designed to be able to transmit and receive mutually via the internal bus 400.

  The CPU 401 which is a general-purpose component in the quality assurance device A 004, the memory 402, the storage device 403, the user interface 404, and the communication interface 405 are the CPU 101 of the production / operation management device A001 shown in FIG. Since the memory 102, the storage device 103, the user interface 104, and the communication interface 105 have the same functions, detailed descriptions thereof are omitted.

  Next, components unique to the present embodiment in the quality assurance device A004 will be described.

  The FMEA management unit 411 registers, in the FMEA management table T430, an FMEA item indicating a possible failure mode and its cause, influence, and importance stored in the memory 402 or the storage device 403, and performs processing such as updating. It is a device to do. Details of the FMEA management table T430 will be described later.

  The symptom correspondence management unit 412 is a device that registers the correspondence relationship between the sign and the FMEA item stored in the memory 402 or the storage device 403 in the sign correspondence management table T440 and performs processing such as updating. Details of the indication correspondence management table T440 will be described later.

  Next, the data configuration of the table used by the operation optimization support system will be described. Here, the configurations of T130, T140, T230, T240, T330, T340, T350, and T360 are the same as in the first embodiment, and thus detailed description will be omitted.

  FIG. 20 is a diagram illustrating a configuration example of the FMEA management table T430. The FMEA management table T430 is a list of FMEAs indicating possible failure modes managed by the FMEA management unit 411 as described in the description of FIG.

  As shown in FIG. 20, the FMEA management table T430 has an item column 431 for storing the identifier of the FMEA item, a mode column 432 for storing the failure mode indicated by the FMEA item, and a cause column storing the cause of the failure mode indicated by the FMEA item. 433, an influence column 434 for storing the effect of the failure mode indicated by the FMEA item, and an importance degree column 435 for storing the importance of the failure mode indicated by the FMEA item.

In the example of FIG. 20, FMEA item F001 is failure mode "broken", cause "degradation", the effect is found to be "stop", the importance of the "27".

  FIG. 21 is a diagram illustrating a configuration example of the sign correspondence management table T440. The symptom correspondence management table T440 is a list of the correspondence between the failure sign and the FMEA item managed by the sign correspondence management unit 412, as described in the description of FIG.

  As shown in FIG. 21, the symptom correspondence management table T440 includes a failure sign column 441 storing an identifier of a failure sign to be diagnosed, a machine column 442 storing an identifier of a machine related to the failure sign, and parts related to the failure sign. The component column 443 stores an identifier, the item column 444 stores an identifier of an FMEA item corresponding to a failure sign, and the like.

  In the example of FIG. 21, it is understood that the machine E001, the part P011, and the failure sign D001 correspond to the FMEA item F001. The failure sign “-” indicates that it is common to all the failure signs.

(2-2) Countermeasure plan presentation processing Next, details of the countermeasure plan presentation processing in the present embodiment will be described. Here, since the processing procedure of S001, S002, S003, S004, S005, S006, S007 and S008 is the same as that of the first embodiment, the detailed description will be omitted.

  In step S 009 of FIG. 13, the countermeasure plan creating unit 113 of the production and operation management apparatus A 001 sends the information on the failure sign and the countermeasure plan stored in the memory 102 or the storage device 103 to the user via the user interface 104. Display relevant FMEA items when presenting.

  With reference to FIG. 22, the countermeasure proposal presentation process in this Embodiment is demonstrated.

  As shown in FIG. 22, first, the countermeasure proposal creation unit 113 of the production / operation management apparatus A 001 sends the machine “E 001 stored in the memory 102 or storage device 103 to the quality assurance apparatus A 004 via the communication interface 105. , The part "P011" and the failure sign "D001" are transmitted, and the FMEA item is requested (S191). Then, the symptom correspondence management unit 412 of the quality assurance apparatus A 004 receives the machine “E001”, the component “P011”, and the failure sign “D001” via the communication interface 405, and stores it in the memory 402 or the storage device 403. .

  Then, the symptom correspondence management unit 412 of the quality assurance apparatus A 004 is based on the machine “E001”, the component “P011”, and the failure sign “D001” stored in the memory 402 or the storage device 403, and the sign correspondence management table T440. The FMEA item “F001” (record 445 in FIG. 21) and the FMEA item “F002” (record 446 in FIG. 21) are searched for and acquired (S192).

  Next, based on the FMEA item "F001" and the FMEA item "F002" acquired in step S192, the indication management unit 412 of the quality assurance apparatus A004 relates the information from the FMEA management table T430 through the FMEA management unit. The information on the failure mode (record 436 and record 437 in FIG. 20) is acquired and transmitted to the production / operation management apparatus A 001 via the communication interface 405 (S193). Then, the countermeasure proposal creation unit 113 of the production and operation management apparatus A 001 receives the information on the failure mode of the FMEA item “F001” and the FMEA item “F002” via the communication interface 105, and the memory 102 or the storage device 103. Store in

  Next, the countermeasure proposal creation unit 113 of the production and operation management apparatus A 001 has information on failure modes of the FMEA item “F001” and the FMEA item “F002” stored in the memory 102 or the storage device 103 as a failure sign and a countermeasure proposal. And the information on the screen (S194).

  FIG. 23 is a diagram showing an example of presenting a countermeasure plan. Since the display items of C001, C002, C003, C004, C005, C006, C007, C008, C009, C010, C010 and C011 in FIG. 23 are the same as in the first embodiment, the detailed description will be omitted.

  The information on the failure mode of the FMEA item “F001” and the FMEA item “F002” stored in the memory 102 or the storage device 103 is displayed together with the information on the failure sign and the countermeasure plan (display item C101 in FIG. 23).

(2-3) Effect of this Embodiment According to the above-described embodiment, a countermeasure plan can be selected together with FMEA information, so that a user's decision making can be further facilitated.

(3) Third Embodiment (3-1) Configuration of Operation Optimization Support System In the present embodiment, when the production / operation management apparatus A 001 presents a measure plan in the first embodiment. , According to the strategy set in advance by the user.

  With reference to FIG. 24, the structure of each apparatus which comprises an operation optimization assistance system is demonstrated. Here, since the configurations of A002 and A003 are the same as those in the first embodiment, detailed description thereof is omitted.

  FIG. 24 is a diagram illustrating a schematic configuration of the production / operation management apparatus A001. Here, the CPU 101, the memory 102, the storage device 103, the user interface 104, the communication interface 105, the production and operation condition management unit 111, the countermeasure candidate management unit 112, and the countermeasure execution unit 114 Detailed description will be omitted because it is the same as the above.

  The strategy management unit 115 is a device that registers a strategy stored in the memory 102 or the storage device 103 in the strategy management table T150 and performs processing such as updating. Details of the strategy management table T150 will be described later.

  The countermeasure plan preparing unit 113 prepares a countermeasure plan in the same manner as the first embodiment, and selects an optimal countermeasure plan out of the prepared countermeasure plans according to the logic stored in the strategy management table T150. It is a device stored in the storage device 103.

  Next, the data structure of the table used by the operation optimization support system will be described. Here, the configurations of T130, T140, T230, T240, T330, T340, T350, and T360 are the same as in the first embodiment, and thus detailed description will be omitted.

  FIG. 25 is a diagram showing a configuration example of the strategy management table T150. The strategy management table T150 is a list of strategies managed by the strategy management unit 115 as described with reference to FIG.

  As shown in FIG. 25, the strategy management table T150 includes a strategy column 151 for storing the identifier of the strategy, a logic column 152 for storing the logic for realizing the strategy, and a selection column 153 for storing the selection state of the user. Be done.

(3-2) Countermeasure plan presentation processing Next, details of the countermeasure plan presentation processing of the present embodiment will be described. Here, since the processing procedure of S001, S002, S003, S004, S005, S006, S007 and S008 of FIG. 13 is the same as that of the first embodiment, the detailed description will be omitted.

  In step S 009 of FIG. 13, the countermeasure plan creating unit 113 of the production and operation management apparatus A 001 sends the information on the failure sign and the countermeasure plan stored in the memory 102 or the storage device 103 to the user via the user interface 104. At the time of presentation, the information is presented based on the information of the strategy management table T150.

  In the present embodiment, the strategy proposal creating unit 113 of the production and operation management apparatus A 001 has a selection column "○" from the strategy management table T150 via the strategy management unit. “Importance” and its logic “minimum additional cost below risk threshold” (record 154 in FIG. 25).

  From the countermeasure plans stored in the memory 102 or the storage device 103, the countermeasure plan creating unit 113 of the production and operation management apparatus A001 selects a countermeasure plan that matches the logic "minimum additional cost below risk threshold". . Here, the risk threshold “2000” (record 354 in FIG. 11) of the machine “E001” and the part “P011” is acquired from the operation risk threshold management table T350 via the operation risk constant management unit 311 of the maintenance management device A003. Therefore, if the operation risk is “2000” or less and the additional cost is minimum, the countermeasure proposal “condition change” is used.

  FIG. 26 is a diagram showing an example of presenting a countermeasure plan. Since the display items of C001, C002, C003, C004, C005, C006, C007, C008, C009, C010, C010 and C011 are the same as in the first embodiment, detailed description will be omitted.

  As shown in FIG. 26, the countermeasure proposal “condition change” selected based on the information of the strategy management table T150 is displayed at the top (display item C201 of FIG. 26). The currently selected strategy is also displayed (display item C202 in FIG. 26).

(3-3) Effects of this Embodiment According to the above-described embodiment, a countermeasure plan can be automatically selected according to the strategy selected by the user, so that the user's decision can be made smoothly and accurately.

A001 Production and operation management device 111 Production and operation condition management unit 112 Countermeasure candidate management unit 113 Countermeasure proposal preparation unit 114 Measures execution unit 115 Strategy management unit A002 Production and operation planning device 211 Production and operation capacity management unit 212 Production and operation plan management Part 213 production / operation plan creation part A003 maintenance management apparatus 311 operation risk constant management part 312 operation risk management part 313 operation risk calculation part 314 failure sign detection part A004 quality assurance apparatus 411 FMEA management part 412 sign correspondence management part E001, E002, E003 Machine

Claims (8)

Machine,
A production / operation management device that manages production / operation of the machine;
A production and operation planning device for planning production and operation of the machine;
A maintenance management device that manages the operating state and operating risk of the machine;
Have
The maintenance management device detects a failure sign of the machine,
Using the production and operation plan managed by the production and operation planning device and the operation risk managed by the maintenance management device, the production and operation management device proposes measures for failure signs detected by the maintenance management device Operation optimization support system characterized by creating. The maintenance management device
Detecting a failure sign of the machine based on the operation information of the machine;
Calculate the increase amount of deterioration risk of the machine over time,
When the failure sign of the machine is detected, the increase amount of the failure sign risk of the machine is calculated,
The operation optimization according to claim 1, characterized in that the operation risk is updated by adding the increase amount of the aging risk of the machine and the increase amount of the failure sign risk to the current operation risk of the machine. Support system. The production and operation planning device
The production time is calculated by calculating the production time from the production / operation conditions and capacity of the machine and the production amount of the target product included in the production / operation plan for a plurality of countermeasure candidates for failure signs of the machine. The operation optimization support system according to claim 2, wherein, when the remaining production time of the machine is smaller than the remaining production time, the countermeasure candidate is searched as a countermeasure plan. The maintenance management device
4. The risk of the countermeasure plan is calculated by adding an increase amount of the aging risk of the machine corresponding to the selected countermeasure plan to a current increase amount of the machine. Operation optimization support system described. The countermeasure plan created by the production and operation management device, the failure sign detected by the maintenance management device, the production and operation plan created by the production and operation planning device based on the countermeasure plan, and the maintenance management The operation optimization support system according to claim 1, wherein the device displays the operation risk created on the basis of the countermeasure plan and the production / operation plan on a display screen. It has FMEA management device that manages FMEA information to analyze the failure mode of machine and its influence,
The FMEA management device selects an FMEA item corresponding to the failure sign detected by the maintenance management device;
The countermeasure plan prepared by the production and operation management device, the failure sign detected by the maintenance management device, the production and operation plan created by the production and operation planning device based on the countermeasure plan, and the maintenance management The operation optimum according to claim 5, characterized in that the apparatus displays on the display screen together with the operation risk prepared based on the countermeasure plan and the production / operation plan and the FMEA item selected by the FMEA management apparatus. Support system. The production / operation management device selects a countermeasure plan according to the strategy selected by the user,
The countermeasure plan prepared by the production and operation management device, the failure sign detected by the maintenance management device, the production and operation plan created by the production and operation planning device based on the countermeasure plan, and the maintenance management The apparatus displays on the display screen together with the operation risk prepared based on the countermeasure plan and the production and operation plan, the strategy selected by the user, and the countermeasure plan selected by the production and operation management device. The operation optimization support system according to claim 5, wherein A machine, a production / operation management device for managing production / operation of the machine, a production / operation planning device for planning production / operation of the machine, a maintenance management device for managing the operating state and operation risk of the machine An operation optimization support method in an operation optimization support system having
The maintenance management device detecting a failure sign of the machine;
Using the production and operation plan managed by the production and operation planning device and the operation risk managed by the maintenance management device, the production and operation management device proposes measures for failure signs detected by the maintenance management device Step of creating
A method for supporting operation optimization, comprising:

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