JP7432448B2 - Operation loss analysis system and operation loss analysis method - Google Patents

Description

The present invention relates to a technology for analyzing operational loss at a manufacturing site in a factory that produces products.

As background technology, there is Patent Document 1. This bulletin states, ``The operating data includes event data representing events that occur in the machine and state data representing the state of the machine, and the inference section analyzes the event data for past, present, and future events at any given time. The reason for non-operation is inferred based on inference data that includes data on whether or not a machine has occurred, and state data that includes data on the state of the machine in the past, present, and future at any given time. .” is stated.

Japanese Patent Application Publication No. 2019-95879

Social infrastructure system products such as control panels are produced in high-mix, low-volume production, and each product requires different processing equipment and parts. For this reason, compared to mass-produced products, operation losses such as increased preparation time for setup and stagnation time during actual machining are caused by factors such as the manufacturing order, worker skills, and the presence or absence of equipment or component troubles. Occur. Because these products have low repeatability, it is difficult to identify the causes of operational loss, and the study of improvement measures has largely relied on the experience of experts and individual case studies. Therefore, it is important to quickly identify the causes of these operational losses that reduce productivity at manufacturing sites and their influence, and to formulate countermeasures.

On the other hand, Patent Document 1 describes a method of inferring the reason for non-operation from an event occurrence log of equipment and registering the reason in association with the non-operation time. However, these methods analyze the causes of non-operating time itself, such as alarm stoppages that occur in equipment, and the impact of these alarm stoppages, such as increased time for recovery preparation and setup in post-work (operation loss). ) cannot be measured.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide an operation loss analysis system and an operation loss analysis method that can evaluate the effect of equipment stoppage on other operations, including the effect of the operation loss.

In order to solve the above problems, the operation loss analysis system according to the present invention includes operation status information indicating operation status including the operation status of equipment or the work status of workers, and manufacturing products or parts for each of the operation statuses. Based on the operation record of the equipment or the operation record information in which the work performance of the worker is recorded, there is no impact on the operation of the equipment or the work of the worker due to the stoppage of the equipment. A regular time calculation unit that calculates regular work time for each of the operation statuses, and an excess of the regular work hours for each of the operation statuses based on the regular work hours calculated for each operation status and the operation performance information. The present invention is configured as an operation loss analysis system characterized by having an operation loss calculation unit that calculates the amount of time as an operation loss.

According to the present invention, it is possible to evaluate the effect of equipment stoppage including the effect of operation loss on other operations.

It is a figure showing an example of a processing flow in a present example. FIG. 1 is a block diagram showing the overall system configuration related to this embodiment. It is a figure which shows an example of equipment processing product information. It is a figure showing an example of operation record information. It is a figure showing an example of operation status information. It is a figure which shows an example of operation loss analysis history information. It is a figure which shows an example of operating time summary information. It is a figure which shows an example of operation loss influence degree information. It is a figure showing an example of operation loss detailed information. It is a figure showing an example of an input screen in a present example. It is a figure which shows an example of the detailed process flow of process step S120 in a present Example. It is a figure which shows an example of the transition of the abnormality determination flag produced and cleared in process step S1203 or S1206 in a present Example. It is a figure which shows an example of the abnormality determination list produced|generated in process step S1205 in a present Example. It is a figure which shows an example of the regular work time by operation status calculated in process step S130 in a present Example. It is a figure which shows an example of the permissible time by operation status calculated in process step S130 in a present Example. It is a figure which shows an example of the calculation result of the operation loss calculated in process step S140 in a present Example. It is a figure showing an example of an output screen in a present example.

Embodiments of the present invention will be described below with reference to the drawings. The following description and drawings are examples for explaining the present invention, and are omitted and simplified as appropriate for clarity of explanation. The present invention can also be implemented in various other forms. Unless specifically limited, each component may be singular or plural.

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

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

When there are multiple components having the same or similar functions, the same reference numerals may be given different suffixes for explanation. However, if there is no need to distinguish between these multiple components, the subscripts may be omitted in the description.

In addition, in the following explanation, processing performed by executing a program may be explained, but the program is executed by a processor (for example, a CPU (Central Processing Unit) or a GPU (Graphics Processing Unit)). The processor may be the main body of the processing in order to perform the processing using appropriate storage resources (for example, memory) and/or interface devices (for example, communication ports). Similarly, the subject of processing performed by executing a program may be a controller, device, system, computer, or node having a processor. The main body of the processing performed by executing the program may be an arithmetic unit, and may include a dedicated circuit (for example, FPGA (Field-Programmable Gate Array) or ASIC (Application Specific Integrated Circuit)) that performs specific processing. .

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

The operation loss analysis system and operation loss analysis method according to the present embodiment will be described in detail below when applied to the manufacturing site of a factory that produces products and parts. It can be applied to various sites where various products such as devices and equipment are manufactured.

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

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

The input/output unit 100 is for acquiring data necessary for processing by the calculation unit 300 and displaying the processing results, and includes, for example, input devices such as a keyboard and mouse, a communication device for communicating with the outside, and a disk-type storage medium. It consists of a recording and reproducing device, an output device such as a CRT and a liquid crystal monitor, etc.

The storage unit 200 stores input information 210 used in processing by the calculation unit 300 and output information 220 that stores processing results, and is configured with a storage device such as a hard disk drive or memory.

The input information 210 includes equipment processed product information 211, operation performance information 212, and operation status information 213, and these pieces of information will be explained below.

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

The operation performance information 212 is information for managing the operation status and operation time when processing the equipment processing product information 211. For example, as shown in FIG. Contains information on alarm ID, start time, end time, and elapsed time. In the operation record information 212 in FIG. 4, for example, in the record with record ID "1000" and processing ID "100", the operation status ID is "W01" at the beginning, and it starts at "09:00" and is "09:00". 09'' and the elapsed time was ``9 (minutes)''. Further, the alarm ID is information that specifies the type of alarm recorded when the operation status ID becomes alarm stop (in this embodiment, "W04"). The type of alarm indicates an event that may cause a problem in processing the target product, such as a processing defect, tool replacement, line abnormality, or equipment malfunction. Here, details of the operation status will be described later.

The operation status information 213 is information for managing the operation status of various equipment at the manufacturing site that can be obtained as operation logs. For example, as shown in FIG. 5, it includes operation status ID, operation status name, operation loss calculation. Contains flag information. As exemplified below, the operation status information 213 includes the operating status of equipment (or its peripheral equipment) for processing products and parts, and preparations for the processing by the operator such as operating the equipment. (or post-processing).

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

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

The operation loss analysis history information 221 is information for managing the history of using the operation loss analysis system 10, and includes, for example, analysis ID, start period, end period, conditions (equipment), and conditions, as shown in FIG. Contains information on (product type), conditions (processing date), steady-state time tolerance (%), and analysis date and time. In the operation loss analysis history information 221 of FIG. /10/1" to "October 31, 2019", and the equipment, product type, and processing date are not specified (the flag "0" is set for each) as the conditions for the operation loss analysis and aggregation unit (the flag "0" is set for each), and the routine work This indicates that the allowable value for time is up to "10 (%)". The method of inputting and analyzing this information will be described later. Note that, as in the case of the operation status information 213, the regular working time includes the operating time during normal operation of equipment (or its peripheral equipment) for processing products and parts, includes the worker's work time during normal operations such as preparation for the above-mentioned processing (or post-processing).

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

The operation loss impact information 223 manages the results of evaluating the impact of equipment alarms that occurred during the relevant analysis period on stagnation or prolongation of work by workers and equipment processing (hereinafter referred to as operation loss). For example, as shown in FIG. 8, this information includes analysis ID, alarm ID, operation status ID, operation status name, and loss time (h). In the operation loss impact information 223 of FIG. 8, in the period indicated by analysis ID "100", due to the occurrence of alarm ID "A01", "2(h)" is applied to each of operation status IDs "W01" to "W04". ”, “3(h)”, “5(h)”, and “15(h)” are evaluated as having occurred. A method of calculating these loss times will be described later.

The operation loss detailed information 224 is information for managing detailed information for generating the operation loss impact degree information 223, and includes, for example, analysis ID, alarm ID, operation status ID, product type, equipment, as shown in FIG. Contains information on processing date and loss time (minutes). In the operation loss detailed information 224 in Figure 9, during the period indicated by analysis ID "100", alarm ID "A01" occurs for processing date "2019/10/1", product type "A", and equipment "M01". Accordingly, the operation loss given to each of the operation status IDs "W01" to "W04" must be "4 (minutes)", "3 (minutes)", "7 (minutes)", and "30 (minutes)". It shows.

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

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

The arithmetic processing unit 320 acquires information necessary for the processing of the arithmetic processing unit 320 from the input information 210 based on information such as the analysis period and analysis method input by the user from the input/output unit 100, and stores the information in the memory unit 310. A data acquisition unit 321 to store data, an operating time aggregation unit 322 that aggregates the operating time of each piece of equipment in the relevant analysis period from the equipment processing product information 211 and operating performance information 212, and various operation logs of the operating performance information 212. , an abnormal operation log determination unit 323 that determines whether the operation log is steady or abnormal based on whether an alarm stop has occurred, and a normal work time when there is no influence on stagnation due to the occurrence of an alarm stop, etc. a normal time calculation unit 324 that calculates and calculates for each product, equipment, and operation status; an operation loss calculation unit 325 that calculates and calculates the operation loss based on the difference from the normal work time for the abnormal operation log; The alarm-by-alarm operation loss aggregation unit 326 aggregates losses by alarm in the operation performance information 212, and the operation loss analysis history 221 and operation time aggregation information are the results of acquisition, calculation, calculation, and aggregation by each of the above-mentioned processing units, respectively. 222, operation loss influence degree information 223, and a display control section 327 that stores the operation loss detailed information 224 and displays it on the input/output section 100.

Next, the operation of each function in the operation loss analysis system 10 of FIG. 2 will be explained according to the flowchart shown in FIG. 1.

First, in order to analyze the factors that have a large impact on operation loss from the operation history of various equipment at the manufacturing site, the user inputs the period of operation performance to be analyzed from the input screen shown in Figure 10, for example. , by selecting analysis conditions, inputting the normal work time tolerance, and clicking the execution button, processing in the operation loss analysis system 10 can be started. Here, for analysis conditions, select whether to specify items to be used for classifying operation results. If you select "Specified", you can also specify items to be used for classification, such as equipment and product type, processing date, etc. The format is to check the box. Further, the normal working time allowable value has a format in which a threshold value that is allowable when determining operation loss is specified by a deviation ratio (%) from the normal working time or a deviation time (h). In this example, the analysis period shown in Figure 10 (2019/10/1 to 2019/10/31) is input, the analysis condition is selected as ``Unspecified'', and ``10 (%)'' is set as the normal work time allowable value. The case where the information is input will be explained below as an example.

Next, the data acquisition unit 321 acquires the information of the input information 210 based on conditions such as the analysis period that the user inputs from the input/output unit 100 of a terminal, and stores the information in the memory unit 310 together with the conditions. (S100). In this example, it is assumed that the equipment processed product information 211, operation record information 212, and operation status information 213 shown in FIGS. 3 to 5 are obtained as the input information 210, and the various input values shown in FIG. 6 are obtained. , will be explained below. In FIG. 6, the analysis ID is an ID issued each time the execution button is clicked on the input screen of FIG. 10, and is an ID for managing the history of various analysis conditions and results input during analysis. In addition, "Condition (equipment)", "Condition (product type)", and "Condition (processing date)" in Figure 6 correspond to the analysis condition checkboxes on the input screen in Figure 10, and are checked. Items that are included are flagged as "1", and items that are not included are flagged as "0". Here, if "no designation" is selected, all three flags are set to "0".

Then, the operating time aggregation unit 322 aggregates the operating time of each piece of equipment corresponding to the analysis period from the equipment processed product information 211 and the operating performance information 212, and stores it in the memory unit 310 (S110). In the equipment processing product information 211 in Figure 3, extract the record whose processing date corresponds to "2019/10/1 to 2019/10/31", and from the operation record information 212 in Figure 4, have the processing ID of the record. Extract data and aggregate it by equipment. The following description will be made assuming that the operation time (h) for each facility shown in FIG. 7 is generated through the above processing.

After that, the abnormal operation log determination unit 323 determines whether or not there is an alarm stoppage in the operation record information 212 and the operation loss calculation flag in the operation status information 213, and determines whether there is a possibility that an operation loss has occurred due to the influence of the alarm stoppage. A certain abnormal operation log is determined and stored in the memory unit 310 (S120). A detailed flow of this process is shown in FIG. 11 and will be described below.

First, the abnormal operation log determination unit 323 obtains a set of processing IDs for the same equipment and processing date in the equipment processing product information 211, and obtains records with the processing IDs in the operation performance information 212 in order of earliest start time ( S1200). In the equipment processed product information 211 in FIG. 3, the abnormal operation log determination unit 323 acquires the processing IDs "100 to 105" for the equipment "M01" and the processing date "2019/10/1", and obtains the operation performance information in FIG. 212 and first read the data in the first row.

Next, the abnormal operation log determination unit 323 determines whether there is operation performance data to be subjected to abnormality determination (S1201), and if it is determined that there is no operation performance data to be subjected to abnormality determination, the process ends ( If it is determined that there is operational performance data for which abnormality determination is to be performed (S1201; Yes), the process advances to S1202. Here, the abnormal operation log determination unit 323 performs the processing from S1202 on the first line of the operation record information 212 in FIG. 4.

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

After that, the abnormal operation log determination unit 323 determines whether there is an effect of operation loss due to the alarm stop (S1204), and if it is determined that there is an effect of operation loss due to the alarm stop, the process proceeds to the next process (S1204; Yes), and if it is determined that there is no effect of operation loss due to the alarm stop, the process returns to S1200 (S1204; No), and the next operation performance data is read. In this process, the influence of operation loss is determined when an abnormality determination flag, which will be described later, is set, so at this point, the process returns to S1200 and the data on the second line of the operation performance information 212 in FIG. 4 is read.

The abnormal operation log determination unit 323 repeats the above process up to the 8th line of the operation record information 212 in FIG. Since the alarm ID "A01" is set in the data on the 9th line, the abnormal operation log determination unit 323 determines that there is an alarm stop log in the process of S1202, and proceeds to the process of S1203.

Next, the abnormal operation log determination unit 323 sets an abnormality determination flag and stores it in the memory unit 310 (S1203). For example, as shown in FIG. 12, the abnormality determination flag is associated with the performance ID and processing ID when the operation performance information 212 is read, and is set to ``0 (no abnormality)'' or ``1 (abnormality)'' for each operation status ID. This is to manage the results of the determination "Yes)". The column "#1" in FIG. 12 shows the initial state of the abnormality determination flag, and "0" is set for each operation status ID. "#2" indicates the result of executing the process of S1203 on the data in the 9th line of the operation performance information 212 in FIG. ", and all the abnormality flags for each operation status ID are set to "1". Further, the symbol in parentheses is the alarm ID in the operation record data, and here "A01" is set together with the flag.

Then, the abnormal operation log determination unit 323 determines whether there is an influence on the operation loss based on the abnormality determination flag (S1204). Here, the operation status ID in the operation performance data (line 9 in FIG. 4) is "W04", and the abnormal operation log determination unit 323 determines the operation loss calculation flag of the ID in the operation status information 213 in FIG. Get "0". Here, the operation loss calculation flag is information that manages an abnormal operation log determination method for each operation status. The abnormal operation log determination unit 323 indicates that "0" indicates the data when the alarm stop occurred, "1" indicates the data of the same processing ID immediately after the occurrence of the alarm stop, and "2" indicates the data of the next processing ID after the occurrence of the alarm stop. Determined as an abnormal operation log. In the operation status information 213 shown in FIG. 5, the operation loss calculation flag of the operation status ID "W04 (alarm stop)" is "0". The abnormal operation log determining unit 323 determines that the corresponding data is abnormal because the status represents the alarm stop itself. Furthermore, the operation loss calculation flag for the operation status ID “W03 (processing)” is “1”. In processing immediately after an alarm stop occurs, there is a possibility that operation loss due to the influence of the alarm is included in the operation performance data, so the abnormal operation log determination unit 323 determines the corresponding data as abnormal. Furthermore, the operation loss calculation flag for the operation status IDs "W01 (condition setting)" and "W02 (setup)" is "2". After an alarm stop occurs, when processing the next product, there is a possibility that preparation work such as setting conditions and setup is required more than during normal processing, so the abnormal operation log determination unit 323 is determined to be abnormal. At this point, the operation status ID is "W04 (alarm stop)" and the value of the abnormality judgment flag for this status ID (W04 row in column #2 in Figure 12) is "1", so the abnormal operation log The determination unit 323 determines that there is an influence on operation loss, and proceeds to the process of S1205.

Thereafter, the abnormal operation log determination unit 323 writes out the operation performance data determined to be abnormal as an abnormality determination list (S1205). Here, the performance ID "1008" and the operation status ID "W04" are obtained from the 9th line of the operation performance information 212 in FIG. 4, and the alarm ID "A01" is obtained from the abnormality determination flag. The abnormality determination list data is generated as shown in the first line of .

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

By repeating the above process, a transition of the abnormality determination flag as shown in FIG. 12 occurs, and an abnormality determination list shown in FIG. 13 is generated. Here, there are multiple alarm IDs such as "A02, A03" stored in the operation status IDs "W01 to W03" in the "#9" column in FIG. This means that the following alarms occurred continuously (data with performance IDs "1012" and "1013" in Figure 4). In such a case, the abnormal operation log determination unit 323 similarly writes out a plurality of alarm IDs when generating the abnormality determination list in the process of S1205 (performance IDs "1014 to 1017" in FIG. 13). In this way, the abnormal operation log determination unit 323 determines the presence or absence of an alarm recorded in the operation record information 212 and the operation loss calculation flag that indicates the method of determining the abnormal operation log for each operation status stored in the operation status information 213. Based on this, abnormal operation logs in which there is a possibility that operation loss has occurred due to the influence of the alarm are determined in the recorded operation record information 212.

Next, returning to the process flow in FIG. 1, the steady time calculation unit 324 extracts the operation record information 212 that was not determined to be an abnormal operation log in the process of S120, calculates the normal work time for each operation status, and stores the 310 (S130). Since the abnormality determination list determined to be an abnormal operation log in the process of S120 has the performance IDs "1008 to 1020" shown in FIG. 13, in the operation performance information 212 of FIG. and "1021" are extracted as regular operation logs. Then, the steady-state time calculation unit 324 classifies these steady-state operation logs by operation status ID, takes statistical values, and calculates the steady-state working time. In this embodiment, an average value is used as a statistical value. For example, in the operation performance information 212 in FIG. The elapsed time of "1003" and "1006" is "10 (minutes)", which is the average of "9 (minutes)", "11 (minutes)", and "10 (minutes)". Similarly, when the regular time calculation unit 324 calculates the regular working time for the operation status IDs "W02" and "W03", they are "20 (minutes)" and "30 (minutes)", respectively, and the data shown in FIG. 14 is generated. Ru. In this way, the steady time calculation unit 324 calculates the statistical value of the operating time of the equipment or the working time of the worker for each operation status, and calculates the steady working time.

Then, the operation loss calculation unit 325 calculates the excess of the normal time for each operation status with respect to the abnormal operation log as an operation loss (S140). In this processing step, the operation loss calculation unit 325 first generates an allowable value for the normal working time of each operating status ID based on the normal working time allowable value input by the user from the input screen. In the input screen of FIG. 10, since "10 (%)" is entered as the permissible value, an increase of 10% from the normal working time is considered to be within the permissible range (not considered an operation loss). Therefore, when the operation loss calculation unit 325 calculates the allowable time for each operation status ID in FIG. 14, the allowable time data shown in FIG. 15 is generated. Next, the operation loss calculation unit 325 calculates the operation loss for the abnormality determination list in S120 based on the difference between the elapsed time of each operation record data and the permissible time. The operation loss calculation unit 325 obtains the elapsed time of the operation record information 212 of FIG. 4 with respect to the abnormality determination list of FIG. 13, and calculates the difference in allowable time for each operation status of FIG. 15. As a result, the operation loss data for each abnormal operation log shown in FIG. 16 is generated. Here, for the operation status "W04 (alarm stop)", since there is no data on the permissible time, the elapsed time in the operation performance data is directly calculated as the operation loss.

Thereafter, the alarm-by-alarm operation loss aggregation unit 326 distributes and aggregates the operation losses calculated in S140 by alarm type and operation status based on the number of occurrences, time, occurrence period, etc., and stores the results in the memory unit 310 (S150). . First, the alarm-by-alarm operation loss aggregation unit 326 develops the operation loss calculation results in FIG. 16 by alarm ID and operation status, and generates the data shown in FIG. 9. In FIG. 9, data on product type, equipment, and processing date can be generated by tracing the operation performance information 212 in FIG. 4 and the equipment processed product information 211 in FIG. 3 from the performance ID in FIG. In addition, multiple alarm IDs such as "A02, A03" are set that affect the operation loss of the performance IDs "1014 to 1016" in FIG. In this embodiment, FIG. 9 shows the results of equally dividing these operating losses into a plurality of alarm IDs. As for how to allocate the operation loss, 100% may be allocated to the alarm immediately before the operation performance data in which the operation loss occurred, or the closer the alarm, the greater the weighting. Thereafter, the alarm-by-alarm operation loss aggregation unit 326 aggregates these operation loss allocation results by alarm ID and operation status ID, and generates the data shown in FIG. 8. In this way, the alarm-specific operation loss aggregation unit 326 aggregates the operation loss for each of one or more types of alarms that are recorded in the operation performance information 212 and indicate the cause of the operation stoppage of the equipment in association with the operation status.

Finally, the display control unit 327 displays the analysis conditions input from the input unit 100 stored in the memory unit 310, the aggregation result of the operating time, the aggregation result of the operation loss by alarm, and the result of the operation loss calculation, respectively. The information is stored in the operation loss analysis history information 211, the operation time summary information 222, the operation loss influence degree information 223, and the operation loss detailed information 224, and displayed on the input/output unit 100 (S160). FIG. 17 shows an example of the output screen in this embodiment.

At the top of this screen, the display control unit 327 displays the information of the analysis ID input on the input screen of FIG. 10 and stored in the operation loss analysis history information 221 of FIG. 6. If you switch the analysis ID (analysis date and time) of this cell using the pull-down menu, the corresponding past operation loss analysis results can be displayed on the screen below.

Next, in the second upper row of this screen, the display control unit 327 displays the total operating time of the equipment in the operating time summary information 222 of FIG. 7, and the operating loss of all alarms in the operating loss impact information 223 of FIG. The total is displayed, and the result of calculating the operating rate based on these ratios is displayed. This makes it possible to grasp the percentage of operation loss during the analysis period, and to confirm whether there is a problem in which the operation rate decreases due to alarm stoppage, etc.

In the middle part of this screen, the display control unit 327 displays the operation loss aggregation results for each alarm ID and the operation loss breakdown for each operation status in the operation loss impact degree information 223 of FIG. 8. Additionally, by selecting "▼" in the first row of each item, it is possible to control the display order and filter values. Further, the display control unit 327 displays an accumulation graph of operation loss for each alarm and the cumulative ratio of the operation loss of all alarms as a Pareto chart at the bottom of the table. This makes it possible to understand which alarms should be dealt with on a priority basis, their degree of impact, and the point at which the impact occurs (operation status) during the analysis period, and to efficiently consider ways to reduce operational loss. Can be done.

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

As described above, in this embodiment, the steady time calculation unit 324 uses the operation status information 213 indicating the operation status including the operation status of the equipment or the work status of the worker, and the operation status information 213 for manufacturing products or parts for each of the above operation statuses. Based on the operation performance information 212 in which the operation performance of the above-mentioned equipment or the work performance of the above-mentioned worker is recorded, there is no impact on the operation of the equipment or the stagnation of the work of the worker due to the stoppage of the operation of the equipment. The regular work time is calculated for each operation status, and the operation loss calculation unit 325 calculates the regular work time for each operation status based on the regular work time calculated for each operation status and the operation performance information 212. The excess amount is calculated as operation loss. Therefore, for example, even for work on products and parts with low repeatability, it is possible to measure the degree of influence of a reduction in the operating rate on other work, such as stopping equipment due to an alarm generated in the equipment. More specifically, even in factories that produce high-mix, low-volume products, based on the operating performance data of each piece of equipment over time and the operating status of equipment such as alarm stoppages, it is possible to analyze the impact that alarm stoppages have on other operations. It becomes possible to evaluate including the impact of operation loss. As a result, it is now possible to prioritize improvement measures for the types of alarms and operating conditions that have a large impact on operation loss, and to carry out improvement activities aimed at improving equipment utilization rates and increasing throughput. Support will be available.

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

Claims (4)

Operation status information indicating the operation status including the operation status of the equipment or the work status of the worker, and the operation record of the equipment or the work record of the worker for manufacturing products or parts for each operation status are recorded. a steady time calculation unit that calculates, for each operation status, a steady work time that does not affect the operation of the equipment or the work of the workers due to the stoppage of the equipment, based on the operation performance information;
an operation loss calculation unit that calculates an excess of the regular work time for each operation status as an operation loss based on the regular work time calculated for each operation status and the operation performance information,
In the operation performance information, one or more types of alarms indicating a cause of operation stoppage of the equipment are recorded in association with the operation status,
an alarm-by-alarm operation loss aggregation unit that aggregates the operation loss for each alarm;
The operation record information is calculated based on the presence or absence of the alarm recorded in the operation record information and the operation loss calculation flag indicating the method of determining the abnormal operation log for each operation status stored in the operation status information. an abnormal operation log determination unit that determines an abnormal operation log in which the operation loss may have occurred due to the influence of the alarm;
An operation loss analysis system characterized by having. The operation loss analysis system according to claim 1,
The steady time calculation unit calculates statistical values of the operating time of the equipment or the working time of the worker for each of the operating statuses, and calculates the steady working time.
An operation loss analysis system characterized by: An operation loss analysis method performed by a computer,
The steady time calculation unit calculates the operation status information indicating the operation status including the operation status of the equipment or the work status of the worker, and the operation record of the equipment or the worker for manufacturing the product or parts for each operation status. Based on the operation performance information in which the work performance is recorded, the regular operation time that does not affect the operation of the equipment or the work of the worker due to the stoppage of the equipment is calculated for each of the operation status,
In the case where the operation loss calculation unit calculates the excess of the regular work time for each operation status as an operation loss based on the regular work time calculated for each operation status and the operation performance information,
In the operation performance information, one or more types of alarms indicating a cause of operation stoppage of the equipment are recorded in association with the operation status,
an alarm-by-alarm operation loss aggregation unit aggregates the operation loss for each alarm;
An abnormal operation log determination unit based on the presence or absence of the alarm recorded in the operation performance information and an operation loss calculation flag indicating a method of determining abnormal operation logs for each operation status stored in the operation status information. determining an abnormal operation log in which the operation loss may have occurred due to the influence of the alarm from among the operation record information;
An operation loss analysis method characterized by the following. The operation loss analysis method according to claim 3 ,
The steady time calculation unit calculates the statistical value of the operating time of the equipment or the working time of the worker for each of the operating statuses, and calculates the steady working time.
An operation loss analysis method characterized by the following.

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