WO2017212552A1 - Data processing device, data processing method, and data processing program - Google Patents

Data processing device, data processing method, and data processing program Download PDF

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Publication number
WO2017212552A1
WO2017212552A1 PCT/JP2016/066938 JP2016066938W WO2017212552A1 WO 2017212552 A1 WO2017212552 A1 WO 2017212552A1 JP 2016066938 W JP2016066938 W JP 2016066938W WO 2017212552 A1 WO2017212552 A1 WO 2017212552A1
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Prior art keywords
user
data processing
database
countermeasure
factor
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PCT/JP2016/066938
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French (fr)
Japanese (ja)
Inventor
大貴 中原
鴇矢 悟
古澤 康一
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三菱電機株式会社
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Priority to PCT/JP2016/066938 priority Critical patent/WO2017212552A1/en
Priority to JP2016564345A priority patent/JPWO2017212552A1/en
Priority to TW105123545A priority patent/TW201743272A/en
Publication of WO2017212552A1 publication Critical patent/WO2017212552A1/en

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    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/418Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/30Computing systems specially adapted for manufacturing

Definitions

  • the present invention relates to a data processing device, a data processing method, and a data processing program.
  • Patent Documents 1 to 3 A system that can cope with a problem without relying on determination based on the search or search operation is disclosed (for example, Patent Documents 1 to 3).
  • Coping method is a method for coping with a problem that has occurred.
  • the problem is, for example, a production problem such as a production line stoppage.
  • a “data change” is a change in the collected data associated with the problem. Collected data is data collected at a factory.
  • factor the cause of the problem
  • the information on the “factor” is not essential.
  • Patent Documents 1 to 3 do not show an effective method for acquiring the combination information.
  • Patent Documents 1 to 3 it is assumed that an operator inputs the above combination information using key-in means, or prepares the above combination information in advance. However, it takes much time to manually input the combination information using the key-in means. For this reason, it is not realistic for an operator to create the above combination information while operating the factory.
  • the factors that stop the production line and the countermeasures differ depending on the factories and facilities, it is difficult to generalize them and it is necessary to create them for each factories and facilities. That is, it is difficult to prepare the combination information in advance.
  • the main object of the present invention is to make it possible to efficiently accumulate changes in collected data related to a problem and how to deal with the problem when a problem occurs in each factory.
  • the data processing apparatus When a production problem occurs in the factory, a designation requesting unit that requests the user to designate a countermeasure for the problem; A database registration unit for registering a countermeasure specified by the user in response to a request from the designation request unit in a database in association with a change in the collected data collected in the factory related to the problem;
  • the user when a production problem occurs, the user is requested to specify a method for dealing with the problem. Then, the countermeasure specified by the user is registered in the database in association with the change in the collected data related to the problem. For this reason, according to this invention, the change of the collection data relevant to the problem which generate
  • FIG. 3 is a diagram showing an outline of a processing procedure using the data processing apparatus according to the first embodiment.
  • FIG. 3 is a diagram illustrating an example of a system configuration according to the first embodiment.
  • FIG. 3 is a diagram illustrating a hardware configuration example of the data processing device according to the first embodiment.
  • FIG. 3 is a diagram illustrating a functional configuration example of the data processing device according to the first embodiment.
  • the flowchart figure which shows the operation example at the time of presenting the factor which concerns on Embodiment 1, and a countermeasure.
  • FIG. 6 is a diagram illustrating an example of an index related to productivity according to the first embodiment.
  • the figure which shows the example of the factor information database which concerns on Embodiment 1.
  • FIG. 1 is a diagram showing an outline of a processing procedure using the data processing apparatus according to the first embodiment.
  • FIG. 3 is a diagram illustrating an example of a system configuration according to the first embodiment.
  • FIG. 3 is a diagram illustrating a hardware configuration example of the
  • FIG. 3 is a flowchart showing an operation example involving mode switching according to the first embodiment.
  • Embodiment 1 FIG. ***Overview***
  • productivity has decreased below a threshold value as a production problem in a factory.
  • the data processing apparatus requests a user (for example, a worker in a factory) to specify a method for dealing with the decline in productivity.
  • the coping method specified by the user is registered in the database in association with the change in the collected data collected at the factory, which is related to the decrease in productivity.
  • FIG. 1 shows an outline of a processing procedure using the data processing apparatus according to the present embodiment.
  • the data processing device generates an index relating to factory productivity.
  • the data processing apparatus analyzes the productivity index, and extracts changes in the collected data related to the decrease in productivity.
  • the data processing apparatus presents the change in the collected data to the user, and requests the user to specify a method for dealing with the decrease in productivity.
  • the problem occurrence time, occurrence location, content, and influence time are presented to the user, and a request is made for designation of a method for dealing with the decrease in productivity.
  • “Problem occurrence time” is the time when productivity falls below a threshold. In the example of FIG.
  • “occurrence location” and “content” indicate changes in collected data related to a decrease in productivity.
  • the “influence time” is the time required from the time when productivity becomes less than the threshold to the time when the productivity exceeds the threshold.
  • the user designates a method for dealing with the decrease in productivity in the data processing apparatus.
  • the data processing apparatus may be able to use an electronic manual when a user specifies a countermeasure.
  • the data processing apparatus extracts items in which “Line 1 facility A” or “Error ⁇ ” is described in an electronic manual, and presents the extracted items to the user.
  • the data processing apparatus extracts “5.4.2 Perform part b adjustment work” and the user does not manually input the countermeasure “Perform part b adjustment work”.
  • a countermeasure is specified by quoting “5.4.2 Perform adjustment work for adjustment of part b”.
  • the data processing apparatus changes the collected data observed when the productivity drops below the threshold (“equipment A”, “the number of occurrences of error ⁇ increases”), and a countermeasure ( “Adjust part b” is registered in the database.
  • a countermeasure “Adjust part b” is registered in the database.
  • “change in the number of occurrences of the error ⁇ in the facility A” that is a change in data is associated with “the adjustment work for part b” is performed as a countermeasure. It is done.
  • the factor specified by the user is also associated with the data change and the countermeasure. FIG. 7 will be described later.
  • the data processing apparatus collects a countermeasure execution history (hereinafter also referred to as an operation history), and uses the time stamp to collect the collected execution history in association with a countermeasure and a change in the collected data.
  • FIG. 1 as indicated by reference numeral 114, “Adjustment of parts b” and “Restart of equipment A” are performed in the equipment A.
  • the data processing apparatus uses the operation time and contents indicated by reference numeral 114 to change the collected data ("equipment A", "increased number of occurrences of error ⁇ ") and the countermeasure specified by the user ("adjustment of part b").
  • the work may be registered in the database in association with “
  • the data processing apparatus requests only the user to specify the countermeasure, but may request the user to specify the factor of the productivity decrease.
  • the factor designated by the user is registered in the database in association with the countermeasure and the change in the collected data.
  • the operation history may be registered in the database in association with factors, countermeasures, and changes in collected data.
  • FIG. 2 shows a system configuration example including the data processing apparatus 100 according to the present embodiment.
  • the data processing apparatus 100 generates an index related to productivity in the factory line 300 and analyzes the index related to productivity. Then, when the productivity falls below the threshold, the database is searched based on the collected data change observed when the productivity falls below the threshold, and is correlated with the observed collected data change. Present the cause and the countermeasures. Further, when the corresponding factor and the countermeasure are not registered in the database, the data processing apparatus 100 requests the user to specify the factor of the decrease in productivity and the countermeasure as shown in FIG. Then, the factor designated by the user and the countermeasure are registered in the database in association with the change in the collected data. The operation performed by the data processing apparatus 100 corresponds to a data processing method.
  • the factory line 300 includes equipment 301 to equipment 305.
  • the number of facilities is five, but there is no restriction on the number of facilities.
  • Each facility is connected to the network 401, and the operation data (error information, etc.) of the facility and the time stamp generated by the sensor when the product passes between the facilities are accumulated in the collected data server device 200 as collected data.
  • the product is an article distributed on the factory line 300. Products include semi-finished products, finished products, and parts.
  • the collected data server device 200 is connected to the data processing device 100 via the network 402.
  • FIG. 3 shows a hardware configuration example of the data processing apparatus 100.
  • FIG. 4 shows a functional configuration example of the data processing apparatus 100.
  • the data processing device 100 is a computer that includes a processor 11, a memory 12, a storage 13, a communication device 14, an input device 15, and a display device 16 connected to a bus.
  • the processor 11 is a CPU (Central Processing Unit) that executes a program.
  • the processor 11 executes a program that realizes the functions of the communication processing unit 101, the productivity management unit 103, the factor analysis unit 105, the display processing unit 107, the factor information addition unit 108, and the input processing unit 109 shown in FIG. These programs are stored in the storage 13. These programs are loaded into the memory 12 and sequentially executed by the processor 11.
  • a program for realizing the display processing unit 107 and the factor information adding unit 108 corresponds to a data processing program.
  • the storage 13 implements the collection database 102, the productivity database 104, the factor information database 106, and the manual database 110 shown in FIG.
  • the memory 12 is, for example, a RAM (Random Access Memory).
  • the storage 13 is, for example, a flash memory, an HDD (Hard Disk Drive), or the like.
  • the communication device 14 is, for example, a communication board.
  • the input device 15 is, for example, a mouse or a keyboard.
  • the display device 16 is, for example, a display.
  • FIG. 4 a functional configuration example of the data processing apparatus 100 will be described.
  • the solid line of the arrow of FIG. 4 represents the calling relationship
  • the broken line arrow represents the flow of data between the processing module and the database.
  • the communication processing unit 101 receives collected data from the collected data server device 200 via the communication device 14 and stores the received collected data in the collected database 102.
  • Collected data includes, for example, equipment operation data (error information, process wait time, etc.), product passage data (including the passage time of each product at a specific point on the production line), equipment operation history, and power data. It is. Note that the communication processing unit 101 receives collected data from the collected data server device 200 in real time as much as possible, and stores the received collected data in the collected database 102.
  • the productivity management unit 103 uses the collected data stored in the collection database 102 to calculate an index related to productivity, and stores the calculated index in the productivity database 104. For example, the productivity management unit 103 calculates the production amount per hour from the passing data of the product by the sensor as an index relating to productivity.
  • the factor analysis unit 105 monitors the productivity index stored in the productivity database 104. Then, the factor analysis unit 105 detects a change in the collected data from the collection database 102 when the productivity falls below the threshold value. After that, the factor analysis unit 105 acquires the factor and the countermeasure from the factor information database 106 using the detected change in the collected data as a key. Then, the factor analysis unit 105 instructs the display processing unit 107 to display the acquired factor and the countermeasure. Alternatively, the factor analysis unit 105 instructs the factor information addition unit 108 to add a set of factors, countermeasures, and collected data changes.
  • the factor information database 106 stores the following three types of information in association with each other. ⁇ Changes in collected data (Example: Increase in the number of occurrences of error ⁇ in facility A, decrease in humidity near facility B, etc.) ⁇ Factors of productivity decline ⁇ How to deal with productivity decline
  • the display processing unit 107 presents display information to the user via the display device 16. More specifically, the display processing unit 107 outputs to the display device 16 display information indicating the factors acquired by the factor analysis unit 105 and the countermeasures. Further, the display processing unit 107 outputs to the display device 16 display information for requesting the user to specify the cause of the decrease in productivity and the countermeasure. Further, the display processing unit 107 outputs display information indicating the digitized manual items extracted by the factor information adding unit 108 to the display device 16.
  • the factor information adding unit 108 designates the factor of the decrease in productivity and the countermeasure method via the display processing unit 107 based on an instruction from the factor analysis unit 105 when the productivity in the factory falls below the threshold value. To the user. As illustrated in FIG. 1, the factor information adding unit 108 may present a change in the collected data to the user via the display processing unit 107 when requesting the user to specify a factor and a countermeasure. In addition, the factor information adding unit 108 may make it possible to use an electronic manual when a user specifies a factor and a countermeasure. In addition, the factor information adding unit 108 registers the factor and the countermeasure specified by the user in the factor information database 106 in association with the change in the collected data observed when the productivity decreases.
  • the factor information adding unit 108 corresponds to a designation request unit and a database registration unit. The operations performed by the factor information adding unit 108 correspond to a designation request process and a database registration process.
  • the input processing unit 109 receives input from the user by the input device 15.
  • FIG. 5 is a flowchart showing an operation in which the data processing apparatus 100 presents factors and countermeasures to the user.
  • the communication processing unit 101 receives collected data from the collected data server device 200 via the communication device 14, and stores the received collected data in the collected database 102 (step S101). For example, the communication processing unit 101 receives the following collected data. Note that the communication processing unit 101 receives collected data from the collected data server device 200 in real time as much as possible, and stores the received collected data in the collected database 102.
  • -Equipment operation data error information, process waiting time, etc.
  • Product passage data by sensor including the passage time of each product at a specific point on the production line
  • Operation history of equipment Power data
  • the productivity management unit 103 uses the collected data of the collection database 102 to calculate an index related to productivity, and stores the calculation result in the productivity database 104 (S102).
  • the productivity management unit 103 uses, for example, the product passage data from the sensor as the productivity index, and calculates the number of productions per hour (the number of productions within a certain time such as 1 minute, 10 minutes, 1 hour). To do.
  • productivity-related indexes are managed in time series as illustrated in FIG.
  • the factor analysis unit 105 monitors the productivity-related index stored in the productivity database 104. When the productivity-related index falls below the threshold, the factor analysis unit 105 performs the production in the collected data stored in the collection database 102. A change related to the decline in sex is detected (step S103). For example, the factor analysis unit 105 detects a change observed for 5 minutes immediately before the time when the productivity falls below the threshold (step S103). More specifically, the factor analysis unit 105 evaluates the degree of contribution to an index related to productivity as in paragraphs 0047 and 0048 of Patent Document 3 (Japanese Patent Application Laid-Open No. 2015-152933) to reduce productivity. It is conceivable to detect changes in related collected data.
  • the factor analysis unit 105 acquires a factor and a countermeasure from the factor information database 106 using the change in the collected data detected in step S103 as a key (step S104). Then, the factor analysis unit 105 instructs the display processing unit 107 to display the acquisition result. If the factor analysis unit 105 cannot acquire the factor and the countermeasure from the factor information database 106, the data processing apparatus 100 ends the process. Alternatively, the factor analysis unit 105 may instruct the display processing unit 107 only to display the detected change in the collected data.
  • FIG. 7 shows an operation example of the factor analysis unit 105. In FIG. 7, it is assumed that “the number of occurrences of the error ⁇ of the facility A is increased” is obtained as the change in the collected data in step S103.
  • the factor analysis unit 105 searches the factor information database 106 using “the number of occurrences of the error ⁇ of the facility A is increased” as a key, and the factor associated with “the number of occurrences of the error ⁇ of the facility A is increased”. Get a workaround.
  • the factor analysis unit 105 acquires “Frequent errors due to deterioration of part b of facility A” as a factor, and “executes adjustment of part b” as a countermeasure.
  • the display processing unit 107 presents to the user display information in which the factors acquired in step S104 and the countermeasures are described (step S105). For example, the display processing unit 107 presents the display information illustrated in FIG. 8 to the user.
  • FIG. 9 is a flowchart showing an operation in which the data processing apparatus 100 requests the user to specify a factor and a countermeasure, and registers the factor and the countermeasure specified by the user in the factor information database 106.
  • step S103 when the factor analysis unit 105 detects a change in the collected data related to the decrease in productivity, the factor analysis unit 105 adds a record to the factor information database 106 for the detected change in the collected data.
  • the factor information adding unit 108 is instructed (S111).
  • the factor information adding unit 108 requests the user to specify a factor and a countermeasure via the display processing unit 107 (step S112).
  • the factor information adding unit 108 may present the digitized manual of the manual database 110 to the user via the display processing unit 107.
  • the factor information adding unit 108 edits each item such as a chapter, section, item, and table of an electronic manual or electronic procedure manual so that the user can select it.
  • the factor information adding unit 108 deals with factors related to changes in the collected data detected in step S103 from items such as chapters, sections, items, and tables in an electronic manual or electronic procedure manual. Extract the law.
  • the factor information adding unit 108 presents the extracted factor and countermeasure list to the user via the display processing unit 107.
  • step S113 the user may be allowed to specify which change is correct in step S113. By doing in this way, the precision of factor detection can be raised. However, this work is not essential because it increases the time and effort of the user.
  • the production facility itself has a function of displaying a plurality of options for solving the trouble from the trouble state through the user interface of the production facility. The user inputs the content of the countermeasure according to the guidance by the function.
  • the factor information adding unit 108 of the data processing apparatus 100 can also synchronize the input contents of the work contents as the procedures of step S112 and step S113. That is, the selection operation can be performed in parallel with the troubleshooting operation.
  • the user designates a factor and a countermeasure by using the input device 15 at the time when the handling of the trouble that caused the decrease in productivity is completed (step S113).
  • the user designates factors or countermeasures from the list by, for example, a click operation. In this way, by using an electronic manual or the like, it is possible to save the user from manually inputting factors or countermeasures. If the factor is unknown, the user may not specify the factor.
  • the factor information adding unit 108 adds to the factor information database 106 a record in which the factor and countermeasures specified by the user and the change in the collected data detected in step S103 in FIG. S114).
  • step S113 when the user specifies a factor or countermeasure from the list by a click operation, the factor information adding unit 108 generates a link to the factor or countermeasure specified by the user.
  • the record describing the change in the collected data detected in step S103 is added to the factor information database 106.
  • the factor information adding unit 108 may acquire an implementation history (operation history) of countermeasures for the equipment from the collection database 102.
  • the factor information adding unit 108 may add an operation history to a record in which a factor, a countermeasure, and a change in collected data are described. Also regarding this operation history, the factor information adding unit 108 may allow the user to check whether the operation history is correct. By doing in this way, the precision of a countermeasure can be raised. However, this work is not essential because it increases the time and effort of the user.
  • FIG. 10 is a flowchart obtained by integrating the flowchart of FIG. 5 and the flowchart of FIG. Steps S101 to S105 are the same as those shown in FIG. Steps S111 to S114 are the same as those shown in FIG.
  • the factor analysis unit 105 selects an operation mode. Specifically, the factor analysis unit 105 determines whether or not the change in the collected data detected in step S103 is registered in the factor information database 106. When the change of the collected data is registered in the factor information database 106, the process after step S104 in FIG. 5 is selected as the student mode. On the other hand, when the change of the collected data is not registered in the factor information database 106, the factor analysis unit 105 selects the processing after step S111 in FIG. 9 as the teacher mode.
  • step S103 of FIG. 5 and FIG. 10 the process after step S104 or the process after step S115 is performed with the trigger “the productivity index has decreased below the threshold”.
  • the process after step S104 or the process after step S115 may be performed with the occurrence of the problem as exemplified in FIG. ⁇
  • equipment operation is carried out
  • Example: equipment shutdown operation is carried out
  • a stop of equipment is detected from the power data
  • the situation of the equipment may be acquired as an image using a camera, and only the image of the peripheral time of the trigger as described above may be left. By doing in this way, the situation (factor) when the problem occurs and the physical countermeasure for the problem can be left as an image.
  • the storage 13 includes functions of a communication processing unit 101, a productivity management unit 103, a factor analysis unit 105, an indication processing unit 107, a factor information addition unit 108, and an input processing unit 109 (hereinafter collectively referred to as “unit”).
  • an OS Operating System
  • At least a part of the OS is executed by the processor 11.
  • the processor 11 executes a program for realizing the function of “unit” while executing at least a part of the OS.
  • the data processing apparatus 100 may include a plurality of processors.
  • information, data, signal values, and variable values indicating the result of the processing of “unit” are stored in the memory 12, the storage 13, a register in the processor 11, or a cache memory.
  • the program for realizing the function of “unit” may be stored in a portable storage medium such as a magnetic disk, a flexible disk, an optical disk, a compact disk, a Blu-ray (registered trademark) disk, or a DVD.
  • the data processing apparatus 100 may be realized by an electronic circuit such as a logic IC (Integrated Circuit), a GA (Gate Array), an ASIC (Application Specific Integrated Circuit), or an FPGA (Field-Programmable Gate Array).
  • each “unit” is realized as part of an electronic circuit.
  • the processor and the electronic circuit are also collectively referred to as a processing circuit.

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Abstract

In the case where a problem in production arises in a factory, a factor information addition unit (108) requests a user to specify a way of coping with the problem. Further, the factor information addition unit (108) registers the way of coping specified by the user in response to the request in a database with the way of coping associated with a change in collection data that relates to the problem and is collected in the factory.

Description

データ処理装置、データ処理方法及びデータ処理プログラムData processing apparatus, data processing method, and data processing program
 本発明は、データ処理装置、データ処理方法及びデータ処理プログラムに関する。 The present invention relates to a data processing device, a data processing method, and a data processing program.
 従来より、工場では、設備トラブルなどの生産上における問題が発生した場合に、その問題に対処するために、工場の作業員が設備の表示器や設備の外観から発生している問題の内容を把握し、マニュアルの内容や経験から問題の原因を予測し、問題に対処する必要があった。しかし、そのような作業はベテラン作業員の経験に対する依存度が大きく、数値化、ルール化することができず、発生した問題に対して適切な対策を迅速にとることが困難である。このため、トラブルシュートに多大の時間を要することがある。
 このような課題に対して、生産上の問題が発生した際に、収集した設備のデータや過去の実績を利用することで、問題の対処法を作業員に提示し、作業員の知識、経験に基づく判断や検索操作に頼ることなく問題への対処を可能とするシステムが開示されている(例えば、特許文献1~3)。
Conventionally, in the factory, when a problem in production such as equipment trouble occurs, in order to deal with the problem, the worker in the factory can explain the contents of the problem that has occurred from the display of the equipment and the appearance of the equipment. It was necessary to understand and predict the cause of the problem from the contents and experience of the manual, and to deal with the problem. However, such work is highly dependent on the experience of experienced workers, cannot be quantified and ruled, and it is difficult to quickly take appropriate measures against problems that occur. For this reason, a lot of time may be required for troubleshooting.
When a production problem occurs in response to such a problem, using the collected equipment data and past results, the countermeasures for the problem are presented to the worker, and the worker's knowledge and experience A system that can cope with a problem without relying on determination based on the search or search operation is disclosed (for example, Patent Documents 1 to 3).
特開平7-7262号公報Japanese Unexamined Patent Publication No. 7-7262 特開2007-272400号公報JP 2007-272400 A 特開2015-152933号公報Japanese Patent Laying-Open No. 2015-152933
 特許文献1~3のようなシステムを実現する場合、以下の2種類の組み合わせ情報が必要になる。
(1)対処法
(2)データの変化
 上記「対処法」とは、発生した問題への対処法である。問題とは、例えば、生産ラインの停止等の生産上の問題である。「データの変化」とは、問題に関連する、収集データにおける変化である。収集データとは、工場で収集されたデータである。
 また、問題の発生要因(以下、単に「要因」という)が判明している場合には、上記の「対処法」及び「データの変化」に、「要因」を対応付けて管理することが望ましい。なお、「要因」は解明できない場合もあるので、「要因」の情報は必須ではない。
In order to realize a system such as Patent Documents 1 to 3, the following two types of combination information are required.
(1) Coping method (2) Data change The above “coping method” is a method for coping with a problem that has occurred. The problem is, for example, a production problem such as a production line stoppage. A “data change” is a change in the collected data associated with the problem. Collected data is data collected at a factory.
In addition, when the cause of the problem (hereinafter simply referred to as “factor”) is known, it is desirable to manage the “factor” and “data change” in association with the “factor”. . In addition, since the “factor” may not be clarified, the information on the “factor” is not essential.
 特許文献1~3では、上記の組み合わせ情報の有効な取得方法が示されていない。特許文献1~3では、作業員がキーイン手段を用いて上記の組合せ情報を入力すること、又は上記の組み合わせ情報を予め用意しておくことが前提となっている。
 しかし、上記の組み合わせ情報をキーイン手段を用いて手入力しようとすると非常に手間がかかる。このため、作業員が工場の操業をしながら上記の組み合わせ情報を作成することは現実的ではない。一方で、作業員でないと組み合わせ情報を作成することは困難であるという問題がある。
 また、生産ラインを停止させる要因とその対処法は工場や設備によって異なるため、一般化が難しく、工場や設備ごとに作成する必要がある。つまり、上記の組み合わせ情報を予め用意しておくことも困難である。
Patent Documents 1 to 3 do not show an effective method for acquiring the combination information. In Patent Documents 1 to 3, it is assumed that an operator inputs the above combination information using key-in means, or prepares the above combination information in advance.
However, it takes much time to manually input the combination information using the key-in means. For this reason, it is not realistic for an operator to create the above combination information while operating the factory. On the other hand, there is a problem that it is difficult to create combination information unless it is a worker.
Moreover, since the factors that stop the production line and the countermeasures differ depending on the factories and facilities, it is difficult to generalize them and it is necessary to create them for each factories and facilities. That is, it is difficult to prepare the combination information in advance.
 本発明は、工場ごとに、生産上の問題が発生した場合に、当該問題に関連する、収集データにおける変化と、当該問題の対処法とを効率的に蓄積できるようにすることを主な目的とする。 The main object of the present invention is to make it possible to efficiently accumulate changes in collected data related to a problem and how to deal with the problem when a problem occurs in each factory. And
 本発明に係るデータ処理装置は、
 工場において生産上の問題が発生した場合に、前記問題への対処法を指定するようユーザに依頼する指定依頼部と、
 前記指定依頼部の依頼に応じて前記ユーザにより指定された対処法を、前記問題に関連する、前記工場で収集された収集データにおける変化と対応付けてデータベースに登録するデータベース登録部とを有する。
The data processing apparatus according to the present invention
When a production problem occurs in the factory, a designation requesting unit that requests the user to designate a countermeasure for the problem;
A database registration unit for registering a countermeasure specified by the user in response to a request from the designation request unit in a database in association with a change in the collected data collected in the factory related to the problem;
 本発明では、生産上の問題が発生した場合に、当該問題への対処法を指定するようユーザに依頼する。そして、ユーザにより指定された対処法を、問題に関連する収集データの変化と対応付けてデータベースに登録する。このため、本発明によれば、工場ごとに、発生した問題に関連する収集データの変化と、問題への対処法とを効率的に蓄積できる。 In the present invention, when a production problem occurs, the user is requested to specify a method for dealing with the problem. Then, the countermeasure specified by the user is registered in the database in association with the change in the collected data related to the problem. For this reason, according to this invention, the change of the collection data relevant to the problem which generate | occur | produced and the coping method to a problem can be efficiently accumulate | stored for every factory.
実施の形態1に係るデータ処理装置を用いた処理手順の概要を示す図。FIG. 3 is a diagram showing an outline of a processing procedure using the data processing apparatus according to the first embodiment. 実施の形態1に係るシステム構成例を示す図。FIG. 3 is a diagram illustrating an example of a system configuration according to the first embodiment. 実施の形態1に係るデータ処理装置のハードウェア構成例を示す図。FIG. 3 is a diagram illustrating a hardware configuration example of the data processing device according to the first embodiment. 実施の形態1に係るデータ処理装置の機能構成例を示す図。FIG. 3 is a diagram illustrating a functional configuration example of the data processing device according to the first embodiment. 実施の形態1に係る要因と対処法を提示する際の動作例を示すフローチャート図。The flowchart figure which shows the operation example at the time of presenting the factor which concerns on Embodiment 1, and a countermeasure. 実施の形態1に係る生産性に関する指標の例を示す図。FIG. 6 is a diagram illustrating an example of an index related to productivity according to the first embodiment. 実施の形態1に係る要因情報データベースの例を示す図。The figure which shows the example of the factor information database which concerns on Embodiment 1. FIG. 実施の形態1に係る要因と対処法の提示例を示す図。The figure which shows the example which shows the factor which concerns on Embodiment 1, and a countermeasure. 実施の形態1に係る要因と対処法を要因情報データベースに登録する際の動作例を示すフローチャート図。The flowchart figure which shows the operation example at the time of registering the factor which concerns on Embodiment 1, and a countermeasure in a factor information database. 実施の形態1に係るモード切替を伴う動作例を示すフローチャート図。FIG. 3 is a flowchart showing an operation example involving mode switching according to the first embodiment.
 以下、本発明の実施の形態について、図を用いて説明する。以下の実施の形態の説明及び図面において、同一の符号を付したものは、同一の部分または相当する部分を示す。 Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description of the embodiments and drawings, the same reference numerals denote the same or corresponding parts.
実施の形態1.
***概要***
 本実施の形態では、工場における生産上の問題として、生産性が閾値未満に低下したことを想定する。そして、本実施の形態では、生産性が閾値未満に低下した場合に、データ処理装置が、生産性の低下への対処法を指定するようユーザ(例えば、工場での作業員)に依頼し、ユーザにより指定された対処法を、生産性の低下に関連する、工場で収集された収集データにおける変化と対応付けてデータベースに登録する。
Embodiment 1 FIG.
***Overview***
In the present embodiment, it is assumed that productivity has decreased below a threshold value as a production problem in a factory. In the present embodiment, when the productivity falls below the threshold, the data processing apparatus requests a user (for example, a worker in a factory) to specify a method for dealing with the decline in productivity. The coping method specified by the user is registered in the database in association with the change in the collected data collected at the factory, which is related to the decrease in productivity.
 図1は、本実施の形態に係るデータ処理装置を用いた処理手順の概要を示す。
 本実施の形態では、符号111に示すように、データ処理装置が、工場での生産性に関する指標を生成する。そして、データ処理装置が生産性に関する指標を解析して、生産性の低下に関連する収集データにおける変化を抽出する。そして、データ処理装置は、収集データにおける変化をユーザに提示して、生産性の低下への対処法を指定するようユーザに依頼する。
 具体的には、符号112に示すように、問題発生時刻、発生箇所、内容及び影響時間をユーザに提示して、生産性の低下への対処法の指定を依頼する。「問題発生時刻」は、生産性が閾値未満に低下した時刻である。図1の例では、2016年2月15日9時15分30秒に生産性が閾値未満に低下したことを示す。また、「発生箇所」及び「内容」は、生産性の低下に関連する収集データの変化を示す。図1の例では、工場内の「設備A」で収集された収集データにおいて、生産性が低下した際に「エラーαの発生回数が増加」している。
 また、「影響時間」とは、生産性が閾値未満となってから閾値を超えるまでに要した時間である。
FIG. 1 shows an outline of a processing procedure using the data processing apparatus according to the present embodiment.
In the present embodiment, as indicated by reference numeral 111, the data processing device generates an index relating to factory productivity. Then, the data processing apparatus analyzes the productivity index, and extracts changes in the collected data related to the decrease in productivity. Then, the data processing apparatus presents the change in the collected data to the user, and requests the user to specify a method for dealing with the decrease in productivity.
Specifically, as indicated by reference numeral 112, the problem occurrence time, occurrence location, content, and influence time are presented to the user, and a request is made for designation of a method for dealing with the decrease in productivity. “Problem occurrence time” is the time when productivity falls below a threshold. In the example of FIG. 1, it is shown that productivity fell below a threshold value at 9:15:30 on February 15, 2016. Further, “occurrence location” and “content” indicate changes in collected data related to a decrease in productivity. In the example of FIG. 1, in the collected data collected by “equipment A” in the factory, “the number of occurrences of error α increases” when productivity decreases.
The “influence time” is the time required from the time when productivity becomes less than the threshold to the time when the productivity exceeds the threshold.
 ユーザは、生産性の低下への対処法をデータ処理装置に指定する。なお、データ処理装置は、ユーザが対処法を指定する際に、電子化されたマニュアルを利用できるようにしてもよい。例えば、データ処理装置は、電子化されたマニュアルにおいて「ライン1設備A」又は「エラーα」が記載されている項目を抽出し、抽出した項目をユーザに提示する。図1の例では、データ処理装置が「5.4.2 パーツbの調整作業を実施する」を抽出し、ユーザは、対処法「パーツbの調整作業を実施する」を手入力する代わりに「5.4.2 パーツbの調整の調整作業を実施する」を引用して対処法を指定している。
 そして、データ処理装置は、生産性が閾値未満に低下した際に観測された収集データの変化(「設備A」、「エラーαの発生回数が増加」)と、ユーザにより指定された対処法(「パーツbの調整作業を実施する」)とを対応付けてデータベースに登録する。
 この結果、図7に例示するように、データベースにおいて、データの変化である「設備Aのエラーαの発生回数が増加」と対処法である「パーツbの調整作業を実施する」とが対応付けられる。図7に示すように、ユーザにおいて問題の発生要因が分かっている場合は、ユーザが指定した要因もデータの変化と対処法に対応付けられる。図7については後述する。
The user designates a method for dealing with the decrease in productivity in the data processing apparatus. Note that the data processing apparatus may be able to use an electronic manual when a user specifies a countermeasure. For example, the data processing apparatus extracts items in which “Line 1 facility A” or “Error α” is described in an electronic manual, and presents the extracted items to the user. In the example of FIG. 1, the data processing apparatus extracts “5.4.2 Perform part b adjustment work” and the user does not manually input the countermeasure “Perform part b adjustment work”. A countermeasure is specified by quoting “5.4.2 Perform adjustment work for adjustment of part b”.
Then, the data processing apparatus changes the collected data observed when the productivity drops below the threshold (“equipment A”, “the number of occurrences of error α increases”), and a countermeasure ( “Adjust part b” is registered in the database.
As a result, as illustrated in FIG. 7, in the database, “change in the number of occurrences of the error α in the facility A” that is a change in data is associated with “the adjustment work for part b” is performed as a countermeasure. It is done. As shown in FIG. 7, when the cause of the problem is known by the user, the factor specified by the user is also associated with the data change and the countermeasure. FIG. 7 will be described later.
 また、データ処理装置は、対処法の実施履歴(以下、操作履歴ともいう)を収集し、収集した実施履歴をタイムスタンプを利用して、対処法と、収集データにおける変化とに対応付けてデータベースに登録してもよい。
 図1では、符号114に示すように、設備Aにおいて、「パーツbの調整」と、「設備Aの再起動」が行われている。データ処理装置は、符号114に示す操作時刻と内容を、収集データの変化(「設備A」、「エラーαの発生回数が増加」)と、ユーザにより指定された対処法(「パーツbの調整作業を実施する」)とに対応付けてデータベースに登録してもよい。
In addition, the data processing apparatus collects a countermeasure execution history (hereinafter also referred to as an operation history), and uses the time stamp to collect the collected execution history in association with a countermeasure and a change in the collected data. You may register with.
In FIG. 1, as indicated by reference numeral 114, “Adjustment of parts b” and “Restart of equipment A” are performed in the equipment A. The data processing apparatus uses the operation time and contents indicated by reference numeral 114 to change the collected data ("equipment A", "increased number of occurrences of error α") and the countermeasure specified by the user ("adjustment of part b"). The work may be registered in the database in association with “
 以上の手順により、作業員が日々の業務の中で実施したことを組み合わせ情報としてデータベースに蓄積しやすくなり、その結果として、経験の浅い作業者でもベテランの作業者と同様に問題の解決が可能となる。 The above procedure makes it easy to store what the workers have done in their daily work in the database as combination information, and as a result, even inexperienced workers can solve problems in the same way as experienced workers. It becomes.
 以上では、データ処理装置は、ユーザに対処法の指定のみを依頼しているが、生産性の低下の要因の指定をユーザに依頼してもよい。ユーザが生産性低下の要因を指定した場合は、図7に示すように、ユーザが指定した要因を、対処法と収集データにおける変化とに対応付けてデータベースに登録する。また、操作履歴を、要因と対処法と収集データにおける変化とに対応付けてデータベースに登録してもよい。 In the above, the data processing apparatus requests only the user to specify the countermeasure, but may request the user to specify the factor of the productivity decrease. When the user designates the factor of productivity reduction, as shown in FIG. 7, the factor designated by the user is registered in the database in association with the countermeasure and the change in the collected data. In addition, the operation history may be registered in the database in association with factors, countermeasures, and changes in collected data.
***構成の説明***
 図2は、本実施の形態に係るデータ処理装置100を含むシステム構成例を示す。
*** Explanation of configuration ***
FIG. 2 shows a system configuration example including the data processing apparatus 100 according to the present embodiment.
 データ処理装置100は、工場ライン300における生産性に関する指標を生成し、生産性に関する指標を解析する。そして、生産性が閾値未満に低下している場合に、生産性が閾値未満に低下した際に観測された収集データの変化に基づきデータベースを検索し、観測された収集データの変化と対応付けられている要因と対処法をユーザに提示する。
 また、データ処理装置100は、対応する要因と対処法がデータベースに登録されていない場合に、図1に示したように、生産性の低下の要因と対処法の指定をユーザに依頼する。そして、ユーザが指定した要因と対処法を収集データの変化と対応付けてデータベースに登録する。
 データ処理装置100が行う動作は、データ処理方法に相当する。
The data processing apparatus 100 generates an index related to productivity in the factory line 300 and analyzes the index related to productivity. Then, when the productivity falls below the threshold, the database is searched based on the collected data change observed when the productivity falls below the threshold, and is correlated with the observed collected data change. Present the cause and the countermeasures.
Further, when the corresponding factor and the countermeasure are not registered in the database, the data processing apparatus 100 requests the user to specify the factor of the decrease in productivity and the countermeasure as shown in FIG. Then, the factor designated by the user and the countermeasure are registered in the database in association with the change in the collected data.
The operation performed by the data processing apparatus 100 corresponds to a data processing method.
 工場ライン300には、設備301~設備305が存在する。なお、図2では、設備を5個としているが、設備の数に制約は存在しない。各設備はネットワーク401に接続されており、設備の稼働データ(エラー情報など)や設備間で製品が通過した際にセンサによって生成されたタイムスタンプなどが収集データとして収集データサーバ装置200に蓄積される。製品は、工場ライン300で流通する物品である。製品には、半完成品、完成品、部品が含まれる。
 収集データサーバ装置200は、ネットワーク402を介してデータ処理装置100と接続される。
The factory line 300 includes equipment 301 to equipment 305. In FIG. 2, the number of facilities is five, but there is no restriction on the number of facilities. Each facility is connected to the network 401, and the operation data (error information, etc.) of the facility and the time stamp generated by the sensor when the product passes between the facilities are accumulated in the collected data server device 200 as collected data. The The product is an article distributed on the factory line 300. Products include semi-finished products, finished products, and parts.
The collected data server device 200 is connected to the data processing device 100 via the network 402.
 図3は、データ処理装置100のハードウェア構成例を示す。また、図4は、データ処理装置100の機能構成例を示す。
 先ず、図3を参照して、データ処理装置100のハードウェア構成例を説明する。
FIG. 3 shows a hardware configuration example of the data processing apparatus 100. FIG. 4 shows a functional configuration example of the data processing apparatus 100.
First, a hardware configuration example of the data processing apparatus 100 will be described with reference to FIG.
 データ処理装置100は、バスに接続された、プロセッサ11、メモリ12、ストレージ13、通信装置14、入力装置15、表示装置16を備えるコンピュータである。
 プロセッサ11は、プログラムを実行するCPU(Central Processing Unit)等である。プロセッサ11は、図4に示す通信処理部101、生産性管理部103、要因分析部105、表示処理部107、要因情報追加部108及び入力処理部109の機能を実現するプログラムを実行する。これらプログラムは、ストレージ13で記憶されている。そして、これらプログラムはメモリ12にロードされて、プロセッサ11により順次実行される。
 表示処理部107及び要因情報追加部108を実現するプログラムは、データ処理プログラムに相当する。
 図3では、プロセッサ11がプログラムを実行している状態を模式的に示している。
 また、ストレージ13は、図4に示す収集データベース102、生産性データベース104、要因情報データベース106、マニュアルデータベース110を実現する。
 メモリ12は、例えばRAM(Random Access Memory)等である。
 ストレージ13は、例えばフラッシュメモリ、HDD(Hard Disk Drive)等である。
 通信装置14は、例えば通信ボード等である。
 入力装置15は、例えばマウス、キーボード等である。
 表示装置16は、例えばディスプレイ等である。
The data processing device 100 is a computer that includes a processor 11, a memory 12, a storage 13, a communication device 14, an input device 15, and a display device 16 connected to a bus.
The processor 11 is a CPU (Central Processing Unit) that executes a program. The processor 11 executes a program that realizes the functions of the communication processing unit 101, the productivity management unit 103, the factor analysis unit 105, the display processing unit 107, the factor information addition unit 108, and the input processing unit 109 shown in FIG. These programs are stored in the storage 13. These programs are loaded into the memory 12 and sequentially executed by the processor 11.
A program for realizing the display processing unit 107 and the factor information adding unit 108 corresponds to a data processing program.
FIG. 3 schematically shows a state where the processor 11 is executing a program.
Further, the storage 13 implements the collection database 102, the productivity database 104, the factor information database 106, and the manual database 110 shown in FIG.
The memory 12 is, for example, a RAM (Random Access Memory).
The storage 13 is, for example, a flash memory, an HDD (Hard Disk Drive), or the like.
The communication device 14 is, for example, a communication board.
The input device 15 is, for example, a mouse or a keyboard.
The display device 16 is, for example, a display.
 図4を参照して、データ処理装置100の機能構成例を説明する。
 なお、図4の矢印の実線は呼び出し関係を表し、破線の矢印は処理モジュールとデータベースとの間のデータの流れを表している。
With reference to FIG. 4, a functional configuration example of the data processing apparatus 100 will be described.
In addition, the solid line of the arrow of FIG. 4 represents the calling relationship, and the broken line arrow represents the flow of data between the processing module and the database.
 通信処理部101は、通信装置14により、収集データサーバ装置200から収集データを受信し、受信した収集データを収集データベース102に格納する。収集データは、例えば、設備の稼働データ(エラー情報、工程待ち時間など)、センサによる製品の通過データ(生産ライン上の特定地点における各製品の通過時刻を含む)、設備の操作履歴、電力データである。
 なお、通信処理部101は、可能な限りリアルタイムで収集データサーバ装置200から収集データを受信し、受信した収集データを収集データベース102に格納する。
The communication processing unit 101 receives collected data from the collected data server device 200 via the communication device 14 and stores the received collected data in the collected database 102. Collected data includes, for example, equipment operation data (error information, process wait time, etc.), product passage data (including the passage time of each product at a specific point on the production line), equipment operation history, and power data. It is.
Note that the communication processing unit 101 receives collected data from the collected data server device 200 in real time as much as possible, and stores the received collected data in the collected database 102.
 生産性管理部103は、収集データベース102に格納された収集データを利用して生産性に関する指標を算出し、算出した指標を生産性データベース104に格納する。
 生産性管理部103は、例えば、生産性に関する指標として、時間あたりの生産量をセンサによる製品の通過データから算出する。
The productivity management unit 103 uses the collected data stored in the collection database 102 to calculate an index related to productivity, and stores the calculated index in the productivity database 104.
For example, the productivity management unit 103 calculates the production amount per hour from the passing data of the product by the sensor as an index relating to productivity.
 要因分析部105は、生産性データベース104に格納された生産性に関する指標を監視する。そして、要因分析部105は、生産性が閾値よりも下がった時点における収集データの変化を、収集データベース102から検出する。その後、要因分析部105は、検出した収集データの変化をキーにして要因情報データベース106から要因と対処法を取得する。そして、要因分析部105は、取得した要因と対処法の表示を表示処理部107に指示する。
 もしくは、要因分析部105は、要因情報追加部108に対して、要因、対処法、収集データの変化のセットの追加を指示する。
The factor analysis unit 105 monitors the productivity index stored in the productivity database 104. Then, the factor analysis unit 105 detects a change in the collected data from the collection database 102 when the productivity falls below the threshold value. After that, the factor analysis unit 105 acquires the factor and the countermeasure from the factor information database 106 using the detected change in the collected data as a key. Then, the factor analysis unit 105 instructs the display processing unit 107 to display the acquired factor and the countermeasure.
Alternatively, the factor analysis unit 105 instructs the factor information addition unit 108 to add a set of factors, countermeasures, and collected data changes.
 要因情報データベース106は、以下の3種類の情報を対応付けて記憶する。
 ・収集データの変化(例:設備Aのエラーαの発生回数が増加、設備B付近の湿度低下など)
 ・生産性の低下の要因
 ・生産性の低下への対処法
The factor information database 106 stores the following three types of information in association with each other.
・ Changes in collected data (Example: Increase in the number of occurrences of error α in facility A, decrease in humidity near facility B, etc.)
・ Factors of productivity decline ・ How to deal with productivity decline
 表示処理部107は、表示装置16を介して、ユーザに表示情報を提示する。
 より具体的には、表示処理部107は、要因分析部105により取得された要因と対処法が示される表示情報を表示装置16に出力する。
 また、表示処理部107は、ユーザに生産性の低下の要因と対処法の指定を依頼する表示情報を表示装置16に出力する。更に、表示処理部107は、要因情報追加部108により抽出された、電子化されたマニュアルの項目が示される表示情報を表示装置16に出力する。
The display processing unit 107 presents display information to the user via the display device 16.
More specifically, the display processing unit 107 outputs to the display device 16 display information indicating the factors acquired by the factor analysis unit 105 and the countermeasures.
Further, the display processing unit 107 outputs to the display device 16 display information for requesting the user to specify the cause of the decrease in productivity and the countermeasure. Further, the display processing unit 107 outputs display information indicating the digitized manual items extracted by the factor information adding unit 108 to the display device 16.
 要因情報追加部108は、工場での生産性が閾値未満に低下した場合に、要因分析部105からの指示に基づき、表示処理部107を介して、生産性の低下の要因と対処法の指定をユーザに依頼する。要因情報追加部108は、図1に示したように、ユーザに要因と対処法の指定を依頼する際に、表示処理部107を介して、ユーザに収集データにおける変化を提示してもよい。また、要因情報追加部108は、ユーザが要因及び対処法を指定する際に電子化されたマニュアルを利用できるようにしてもよい。
 また、要因情報追加部108は、ユーザにより指定された要因及び対処法と、生産性が低下した際に観測された収集データの変化とを対応付けて要因情報データベース106に登録する。
 なお、要因情報追加部108は指定依頼部及びデータベース登録部に相当する。また、要因情報追加部108により行われる動作は、指定依頼処理及びデータベース登録処理に相当する。
The factor information adding unit 108 designates the factor of the decrease in productivity and the countermeasure method via the display processing unit 107 based on an instruction from the factor analysis unit 105 when the productivity in the factory falls below the threshold value. To the user. As illustrated in FIG. 1, the factor information adding unit 108 may present a change in the collected data to the user via the display processing unit 107 when requesting the user to specify a factor and a countermeasure. In addition, the factor information adding unit 108 may make it possible to use an electronic manual when a user specifies a factor and a countermeasure.
In addition, the factor information adding unit 108 registers the factor and the countermeasure specified by the user in the factor information database 106 in association with the change in the collected data observed when the productivity decreases.
The factor information adding unit 108 corresponds to a designation request unit and a database registration unit. The operations performed by the factor information adding unit 108 correspond to a designation request process and a database registration process.
 入力処理部109は、入力装置15により、ユーザからの入力を受け付ける。 The input processing unit 109 receives input from the user by the input device 15.
***動作の説明***
 次に、本実施の形態に係るデータ処理装置100の動作を説明する。
 以下では、先ず、生産性が閾値未満に低下した際にデータ処理装置100が要因と対処法をユーザに提示する動作を説明する。次に、データ処理装置100がユーザに要因と対処法の指定を依頼し、ユーザにより指定された要因と対処法を要因情報データベース106に登録する動作を説明する。
*** Explanation of operation ***
Next, the operation of the data processing apparatus 100 according to the present embodiment will be described.
In the following, first, an operation in which the data processing apparatus 100 presents factors and countermeasures to the user when the productivity falls below the threshold will be described. Next, an operation in which the data processing apparatus 100 requests the user to specify a factor and a countermeasure and registers the factor and the countermeasure specified by the user in the factor information database 106 will be described.
 図5は、データ処理装置100がユーザに要因と対処法を提示する動作を示すフローチャートである。 FIG. 5 is a flowchart showing an operation in which the data processing apparatus 100 presents factors and countermeasures to the user.
 先ず、通信処理部101が、通信装置14を介して収集データサーバ装置200から収集データを受信し、受信した収集データを収集データベース102に格納する(ステップS101)。
 通信処理部101は、例えば、以下の収集データを受信する。なお、通信処理部101は、可能な限りリアルタイムで収集データサーバ装置200から収集データを受信し、受信した収集データを収集データベース102に格納する。
 ・設備の稼働データ(エラー情報、工程待ち時間など)
 ・センサによる製品の通過データ(生産ライン上の特定地点における各製品の通過時刻を含む)
 ・設備の操作履歴
  ・電力データ
First, the communication processing unit 101 receives collected data from the collected data server device 200 via the communication device 14, and stores the received collected data in the collected database 102 (step S101).
For example, the communication processing unit 101 receives the following collected data. Note that the communication processing unit 101 receives collected data from the collected data server device 200 in real time as much as possible, and stores the received collected data in the collected database 102.
-Equipment operation data (error information, process waiting time, etc.)
・ Product passage data by sensor (including the passage time of each product at a specific point on the production line)
・ Operation history of equipment ・ Power data
  次に、生産性管理部103が、収集データベース102の収集データを利用して、生産性に関する指標を算出し、算出結果を生産性データベース104に格納する(S102)。
  生産性管理部103は、生産性に関する指標として、例えば、センサによる製品の通過データを利用し、時間あたりの生産数(1分、10分、1時間などの一定時間内の生産数)を算出する。
  生産性データベース104では、生産性に関する指標が、図6に例示するように、時系列で管理される。
Next, the productivity management unit 103 uses the collected data of the collection database 102 to calculate an index related to productivity, and stores the calculation result in the productivity database 104 (S102).
The productivity management unit 103 uses, for example, the product passage data from the sensor as the productivity index, and calculates the number of productions per hour (the number of productions within a certain time such as 1 minute, 10 minutes, 1 hour). To do.
In the productivity database 104, productivity-related indexes are managed in time series as illustrated in FIG.
  要因分析部105は、生産性データベース104に格納された生産性に関する指標を監視しており、生産性に関する指標が閾値未満に低下した場合に、収集データベース102で記憶されている収集データにおける、生産性の低下に関連する変化を検出する(ステップS103)。要因分析部105は、例えば、生産性が閾値未満に低下した時刻の直前5分間に観測された変化を検出する(ステップS103)。
  より具体的には、要因分析部105は、特許文献3(特開2015-152933)の段落0047と段落0048のように、生産性に関する指標への寄与度を評価して、生産性の低下に関連する収集データの変化を検出することが考えられる。
The factor analysis unit 105 monitors the productivity-related index stored in the productivity database 104. When the productivity-related index falls below the threshold, the factor analysis unit 105 performs the production in the collected data stored in the collection database 102. A change related to the decline in sex is detected (step S103). For example, the factor analysis unit 105 detects a change observed for 5 minutes immediately before the time when the productivity falls below the threshold (step S103).
More specifically, the factor analysis unit 105 evaluates the degree of contribution to an index related to productivity as in paragraphs 0047 and 0048 of Patent Document 3 (Japanese Patent Application Laid-Open No. 2015-152933) to reduce productivity. It is conceivable to detect changes in related collected data.
  次に、要因分析部105が、要因情報データベース106から、ステップS103で検出された収集データの変化をキーにして、要因と対処法を取得する(ステップS104)。そして、要因分析部105は、取得結果の表示を表示処理部107に指示する。
  要因分析部105が要因情報データベース106から要因と対処法を取得できなければ、データ処理装置100は処理を終了する。もしくは、要因分析部105が、検出した収集データの変化の表示のみを表示処理部107に指示してもよい。
  図7は、要因分析部105の動作例を示す。図7では、ステップS103で収集データの変化として「設備Aのエラーαの発生回数が増加」が得られたとする。要因分析部105は、「設備Aのエラーαの発生回数が増加」をキーにして要因情報データベース106を検索し、「設備Aのエラーαの発生回数が増加」に対応付けられている要因と対処法を取得する。図7の例では、要因分析部105は、要因として「設備Aのパーツbが劣化することによるエラーが多発」を取得し、対処法として「パーツbの調整作業を実施する」を取得する。
Next, the factor analysis unit 105 acquires a factor and a countermeasure from the factor information database 106 using the change in the collected data detected in step S103 as a key (step S104). Then, the factor analysis unit 105 instructs the display processing unit 107 to display the acquisition result.
If the factor analysis unit 105 cannot acquire the factor and the countermeasure from the factor information database 106, the data processing apparatus 100 ends the process. Alternatively, the factor analysis unit 105 may instruct the display processing unit 107 only to display the detected change in the collected data.
FIG. 7 shows an operation example of the factor analysis unit 105. In FIG. 7, it is assumed that “the number of occurrences of the error α of the facility A is increased” is obtained as the change in the collected data in step S103. The factor analysis unit 105 searches the factor information database 106 using “the number of occurrences of the error α of the facility A is increased” as a key, and the factor associated with “the number of occurrences of the error α of the facility A is increased”. Get a workaround. In the example of FIG. 7, the factor analysis unit 105 acquires “Frequent errors due to deterioration of part b of facility A” as a factor, and “executes adjustment of part b” as a countermeasure.
  次に、表示処理部107が、ステップS104で取得された要因と対処法が記述された表示情報をユーザに提示する(ステップS105)。
  例えば、表示処理部107は、図8に例示する表示情報をユーザに提示する。
Next, the display processing unit 107 presents to the user display information in which the factors acquired in step S104 and the countermeasures are described (step S105).
For example, the display processing unit 107 presents the display information illustrated in FIG. 8 to the user.
  図9は、データ処理装置100がユーザに要因と対処法の指定を依頼し、ユーザにより指定された要因と対処法を要因情報データベース106に登録する動作を示すフローチャートである。 FIG. 9 is a flowchart showing an operation in which the data processing apparatus 100 requests the user to specify a factor and a countermeasure, and registers the factor and the countermeasure specified by the user in the factor information database 106.
 ステップS103において、要因分析部105が生産性の低下に関連する収集データの変化を検出した際に、要因分析部105は、検出した収集データの変化について、要因情報データベース106へのレコードの追加を要因情報追加部108に指示する(S111)。 In step S103, when the factor analysis unit 105 detects a change in the collected data related to the decrease in productivity, the factor analysis unit 105 adds a record to the factor information database 106 for the detected change in the collected data. The factor information adding unit 108 is instructed (S111).
 要因情報追加部108は、表示処理部107を介してユーザに要因と対処法の指定を依頼する(ステップS112)。
 この際、要因情報追加部108は、マニュアルデータベース110の電子化されたマニュアルを表示処理部107を介してユーザに提示してもよい。例えば、要因情報追加部108は、電子化されたマニュアルや電子手順書の章、節、項、表等の各項目をユーザが選択できるように編集する。具体的には、要因情報追加部108は、電子化されたマニュアルや電子手順書の章、節、項、表等の項目から、ステップS103で検出された収集データの変化に関係する要因と対処法を抽出する。そして、要因情報追加部108は、表示処理部107を介して、抽出した要因と対処法のリストをユーザに提示する。
 なお、図5のステップS103において収集データにおける変化が複数検出されている場合は、ステップS113において、どの変化が正しいかをユーザに指定させてもよい。このようにすることで、要因検出の精度を上げることができる。しかしながら、ユーザの手間が増えるため、この作業は必須ではない。
 また、更なる入力手段として、生産設備自体は、生産設備のユーザ・インタフェースを通して、トラブルの状況から、トラブル解決のための複数の対処の選択肢を表示する機能を備える。ユーザは、その機能によるガイダンスに従い、対処の内容を入力する。この作業内容の入力内容について、データ処理装置100の要因情報追加部108は、ステップS112とステップS113の手順として同期させることも可能である。すなわち、トラブルの対処作業と並行して上記選択作業を行うことができる。
The factor information adding unit 108 requests the user to specify a factor and a countermeasure via the display processing unit 107 (step S112).
At this time, the factor information adding unit 108 may present the digitized manual of the manual database 110 to the user via the display processing unit 107. For example, the factor information adding unit 108 edits each item such as a chapter, section, item, and table of an electronic manual or electronic procedure manual so that the user can select it. Specifically, the factor information adding unit 108 deals with factors related to changes in the collected data detected in step S103 from items such as chapters, sections, items, and tables in an electronic manual or electronic procedure manual. Extract the law. Then, the factor information adding unit 108 presents the extracted factor and countermeasure list to the user via the display processing unit 107.
If a plurality of changes in the collected data are detected in step S103 in FIG. 5, the user may be allowed to specify which change is correct in step S113. By doing in this way, the precision of factor detection can be raised. However, this work is not essential because it increases the time and effort of the user.
Further, as a further input means, the production facility itself has a function of displaying a plurality of options for solving the trouble from the trouble state through the user interface of the production facility. The user inputs the content of the countermeasure according to the guidance by the function. The factor information adding unit 108 of the data processing apparatus 100 can also synchronize the input contents of the work contents as the procedures of step S112 and step S113. That is, the selection operation can be performed in parallel with the troubleshooting operation.
 ユーザは、例えば、生産性の低下を引き起こしたトラブルへの対処が完了した時点で、入力装置15を用いて、要因及び対処法を指定する(ステップS113)。
 前述したように、電子化されたマニュアル又は電子手順書から抽出された要因と対処法のリストが提示された場合は、ユーザは例えばクリック動作によりリストから要因又は対処法を指定する。このように、電子化されたマニュアル等を利用することで、ユーザが要因又は対処法を手入力する手間を省くことができる。
 なお、要因が不明な場合は、ユーザは要因を指定しなくてもよい。
For example, the user designates a factor and a countermeasure by using the input device 15 at the time when the handling of the trouble that caused the decrease in productivity is completed (step S113).
As described above, when a list of factors and countermeasures extracted from an electronic manual or electronic procedure manual is presented, the user designates factors or countermeasures from the list by, for example, a click operation. In this way, by using an electronic manual or the like, it is possible to save the user from manually inputting factors or countermeasures.
If the factor is unknown, the user may not specify the factor.
 最後に、要因情報追加部108が、ユーザにより指定された要因及び対処法と、図5のステップS103で検出された収集データにおける変化とが記述されたレコードを要因情報データベース106に追加する(ステップS114)。
 なお、ステップS113においてユーザがクリック動作によりリストから要因又は対処法を指定した場合は、要因情報追加部108は、ユーザが指定した要因又は対処法へのリンクを生成し、生成したリンクと図5のステップS103で検出された収集データにおける変化とが記述されたレコードを要因情報データベース106に追加する。
 また、要因情報追加部108は、図1で例示したように、収集データベース102から設備への対処法の実施履歴(操作履歴)を取得してもよい。そして、要因情報追加部108は、要因と対処法と収集データにおける変化とが記述されるレコードに操作履歴を追加してもよい。なお、この操作履歴に関しても、要因情報追加部108は、正しい操作履歴であるかどうかをユーザに確認させてもよい。このようにすることで、対処法の精度を上げることができる。しかしながら、ユーザの手間が増えるため、この作業は必須ではない。
Finally, the factor information adding unit 108 adds to the factor information database 106 a record in which the factor and countermeasures specified by the user and the change in the collected data detected in step S103 in FIG. S114).
In step S113, when the user specifies a factor or countermeasure from the list by a click operation, the factor information adding unit 108 generates a link to the factor or countermeasure specified by the user. The record describing the change in the collected data detected in step S103 is added to the factor information database 106.
Further, as illustrated in FIG. 1, the factor information adding unit 108 may acquire an implementation history (operation history) of countermeasures for the equipment from the collection database 102. Then, the factor information adding unit 108 may add an operation history to a record in which a factor, a countermeasure, and a change in collected data are described. Also regarding this operation history, the factor information adding unit 108 may allow the user to check whether the operation history is correct. By doing in this way, the precision of a countermeasure can be raised. However, this work is not essential because it increases the time and effort of the user.
 なお、図5のフローチャートと図9のフローチャートを統合したフローチャートを図10に示す。
 ステップS101~S105は、図5に示したものと同じである。
 また、ステップS111~S114は、図9に示したものと同じである。
 ステップS115では、要因分析部105は、動作モードを選択する。具体的には、要因分析部105は、ステップS103で検出された収集データの変化が要因情報データベース106に登録されているか否かを判定する。収集データの変化が要因情報データベース106に登録されている場合は、生徒モードとして、図5のステップS104以降の処理を選択する。一方、収集データの変化が要因情報データベース106に登録されていない場合は、要因分析部105は、教師モードとして、図9のステップS111以降の処理を選択する。
FIG. 10 is a flowchart obtained by integrating the flowchart of FIG. 5 and the flowchart of FIG.
Steps S101 to S105 are the same as those shown in FIG.
Steps S111 to S114 are the same as those shown in FIG.
In step S115, the factor analysis unit 105 selects an operation mode. Specifically, the factor analysis unit 105 determines whether or not the change in the collected data detected in step S103 is registered in the factor information database 106. When the change of the collected data is registered in the factor information database 106, the process after step S104 in FIG. 5 is selected as the student mode. On the other hand, when the change of the collected data is not registered in the factor information database 106, the factor analysis unit 105 selects the processing after step S111 in FIG. 9 as the teacher mode.
 なお、以上では、図5及び図10のステップS103において、「生産性に関する指標が閾値未満に低下した」ことをトリガーとしてステップS104以降の処理又はステップS115以降の処理が行われているが、以下に例示するような問題が工場生産において生じたことをトリガーにしてステップS104以降の処理又はステップS115以降の処理が行われるようにしてもよい。
 ・設備の操作が実施された場合(例:設備の停止操作が実施された)
 ・設備がイベントを発行した場合(例:設備が部品切れによって停止するイベントを発行した)
 ・電力データから設備の停止を検知した場合(例:設備の消費電力(電流)値が閾値を下回った)
In the above, in step S103 of FIG. 5 and FIG. 10, the process after step S104 or the process after step S115 is performed with the trigger “the productivity index has decreased below the threshold”. The process after step S104 or the process after step S115 may be performed with the occurrence of the problem as exemplified in FIG.
・ When equipment operation is carried out (Example: equipment shutdown operation is carried out)
-When the equipment issues an event (Example: The equipment issues an event that stops due to out of parts)
-When a stop of equipment is detected from the power data (Example: The power consumption (current) value of the equipment falls below the threshold)
 なお、生産ラインの各設備の処理時間がアンバランスであることによって工程待ちが発生して設備が停止することが考えられる。そのような場合は停止した設備自体には問題が無いと考えられるため、工程待ちに関する情報を組み合わせることで、本当の問題だけをトリガーとして扱えるようにすることが考えられる。 It should be noted that due to the unbalanced processing time of each facility on the production line, it is conceivable that a process wait occurs and the facility stops. In such a case, it is considered that there is no problem in the stopped equipment itself, so it is possible to combine only information related to process waiting so that only a real problem can be handled as a trigger.
 また、工作機械などの動きが多い設備に対して、カメラを利用して設備の状況を映像として取得し、上記のようなトリガーの周辺時間の映像だけを残すようにしてもよい。このようにすることで、問題が発生した時の状況(要因)と問題への物理的な対処法を映像として残すことができる。 Also, for equipment with a lot of movement such as machine tools, the situation of the equipment may be acquired as an image using a camera, and only the image of the peripheral time of the trigger as described above may be left. By doing in this way, the situation (factor) when the problem occurs and the physical countermeasure for the problem can be left as an image.
***実施の形態の効果***
 本実施の形態では、生産上の問題が発生した場合に、当該問題への対処法を指定するようユーザに依頼する。そして、ユーザにより指定された対処法を、問題に関連する収集データの変化と対応付けてデータベースに登録する。このため、本発明によれば、工場ごとに、発生した問題に関連する収集データの変化と、問題への対処法とを効率的に蓄積できる。
*** Effect of the embodiment ***
In the present embodiment, when a production problem occurs, the user is requested to designate a method for dealing with the problem. Then, the countermeasure specified by the user is registered in the database in association with the change in the collected data related to the problem. For this reason, according to this invention, the change of the collection data relevant to the problem which generate | occur | produced and the coping method to a problem can be efficiently accumulate | stored for every factory.
***ハードウェア構成の説明***
 最後に、データ処理装置100のハードウェア構成の補足説明を行う。
 ストレージ13には、通信処理部101、生産性管理部103、要因分析部105、示処理部107、要因情報追加部108及び入力処理部109(以下、これらをまとめて「部」という)の機能を実現するプログラムの他に、OS(Operating System)も記憶されている。
 そして、OSの少なくとも一部がプロセッサ11により実行される。
 プロセッサ11はOSの少なくとも一部を実行しながら、「部」の機能を実現するプログラムを実行する。
 図3では、1つのプロセッサが図示されているが、データ処理装置100が複数のプロセッサを備えていてもよい。
 また、「部」の処理の結果を示す情報やデータや信号値や変数値が、メモリ12、ストレージ13又はプロセッサ11内のレジスタ又はキャッシュメモリに記憶される。
 また、「部」の機能を実現するプログラムは、磁気ディスク、フレキシブルディスク、光ディスク、コンパクトディスク、ブルーレイ(登録商標)ディスク、DVD等の可搬記憶媒体に記憶されてもよい。
*** Explanation of hardware configuration ***
Finally, a supplementary description of the hardware configuration of the data processing apparatus 100 will be given.
The storage 13 includes functions of a communication processing unit 101, a productivity management unit 103, a factor analysis unit 105, an indication processing unit 107, a factor information addition unit 108, and an input processing unit 109 (hereinafter collectively referred to as “unit”). In addition to a program for realizing the above, an OS (Operating System) is also stored.
At least a part of the OS is executed by the processor 11.
The processor 11 executes a program for realizing the function of “unit” while executing at least a part of the OS.
Although one processor is illustrated in FIG. 3, the data processing apparatus 100 may include a plurality of processors.
In addition, information, data, signal values, and variable values indicating the result of the processing of “unit” are stored in the memory 12, the storage 13, a register in the processor 11, or a cache memory.
The program for realizing the function of “unit” may be stored in a portable storage medium such as a magnetic disk, a flexible disk, an optical disk, a compact disk, a Blu-ray (registered trademark) disk, or a DVD.
 また、「部」を、「回路」又は「工程」又は「手順」又は「処理」に読み替えてもよい。
 また、データ処理装置100は、ロジックIC(Integrated Circuit)、GA(Gate Array)、ASIC(Application Specific Integrated Circuit)、FPGA(Field-Programmable Gate Array)といった電子回路により実現されてもよい。
 この場合は、「部」は、それぞれ電子回路の一部として実現される。
 なお、プロセッサ及び上記の電子回路を総称してプロセッシングサーキットリーともいう。
In addition, “part” may be read as “circuit” or “process” or “procedure” or “processing”.
The data processing apparatus 100 may be realized by an electronic circuit such as a logic IC (Integrated Circuit), a GA (Gate Array), an ASIC (Application Specific Integrated Circuit), or an FPGA (Field-Programmable Gate Array).
In this case, each “unit” is realized as part of an electronic circuit.
The processor and the electronic circuit are also collectively referred to as a processing circuit.
 11 プロセッサ、12 メモリ、13 ストレージ、14 通信装置、15 入力装置、16 表示装置、100 データ処理装置、101 通信処理部、102 収集データベース、103 生産性管理部、104 生産性データベース、105 要因分析部、106 要因情報データベース、107 表示処理部、108 要因情報追加部、109 入力処理部、110 マニュアルデータベース、200 収集データサーバ装置、300 工場ライン、301 設備、302 設備、303 設備、304 設備、305 設備、401 ネットワーク、402 ネットワーク。 11 processor, 12 memory, 13 storage, 14 communication device, 15 input device, 16 display device, 100 data processing device, 101 communication processing unit, 102 collection database, 103 productivity management unit, 104 productivity database, 105 factor analysis unit 106 factor information database, 107 display processing unit, 108 factor information addition unit, 109 input processing unit, 110 manual database, 200 collection data server device, 300 factory line, 301 facility, 302 facility, 303 facility, 304 facility, 305 facility 401 network, 402 network.

Claims (8)

  1.  工場において生産上の問題が発生した場合に、前記問題への対処法を指定するようユーザに依頼する指定依頼部と、
     前記指定依頼部の依頼に応じて前記ユーザにより指定された対処法を、前記問題に関連する、前記工場で収集された収集データにおける変化と対応付けてデータベースに登録するデータベース登録部とを有するデータ処理装置。
    When a production problem occurs in the factory, a designation requesting unit that requests the user to designate a countermeasure for the problem;
    Data having a database registration unit for registering a coping method designated by the user in response to a request from the designation request unit in a database in association with a change in the collected data collected at the factory related to the problem Processing equipment.
  2.  前記指定依頼部は、
     前記問題の要因を指定するよう前記ユーザに依頼し、
     前記データベース登録部は、
     前記指定依頼部の依頼に応じて前記ユーザにより指定された要因を、前記ユーザにより指定された前記対処法と、前記収集データにおける変化とに対応付けて前記データベースに登録する請求項1に記載のデータ処理装置。
    The designation request unit
    Ask the user to specify the cause of the problem,
    The database registration unit
    The factor specified by the user in response to a request from the specification requesting unit is registered in the database in association with the countermeasure specified by the user and a change in the collected data. Data processing device.
  3.  前記指定依頼部は、
     前記ユーザに前記対処法を指定するよう依頼する際に、前記ユーザに前記収集データにおける変化を提示する請求項1に記載のデータ処理装置。
    The designation request unit
    The data processing apparatus according to claim 1, wherein a change in the collected data is presented to the user when requesting the user to specify the countermeasure.
  4.  前記指定依頼部は、
     前記ユーザが前記対処法を指定する際に電子化されたマニュアルを利用できるようにする請求項1に記載のデータ処理装置。
    The designation request unit
    The data processing apparatus according to claim 1, wherein an electronic manual can be used when the user specifies the countermeasure.
  5.  前記データベース登録部は、
     前記対処法の実施履歴を、前記対処法と、前記収集データにおける変化とに対応付けて前記データベースに登録する請求項1に記載のデータ処理装置。
    The database registration unit
    The data processing apparatus according to claim 1, wherein the implementation history of the countermeasure is registered in the database in association with the countermeasure and a change in the collected data.
  6.  前記指定依頼部は、
     前記工場での生産性が閾値未満に低下した場合に、前記生産性の低下への対処法を指定するようユーザに依頼する請求項1に記載のデータ処理装置。
    The designation request unit
    The data processing apparatus according to claim 1, wherein when the productivity in the factory decreases below a threshold, the user is requested to specify a countermeasure for the decrease in productivity.
  7.  コンピュータが、工場において生産上の問題が発生した場合に、前記問題への対処法を指定するようユーザに依頼し、
     前記コンピュータが、依頼に応じて前記ユーザにより指定された対処法を、前記問題に関連する、前記工場で収集された収集データにおける変化と対応付けてデータベースに登録するデータ処理方法。
    When a computer encounters a production problem in the factory, it asks the user to specify how to deal with the problem,
    A data processing method in which the computer registers a processing method designated by the user in response to a request in a database in association with a change in collected data collected at the factory related to the problem.
  8.  工場において生産上の問題が発生した場合に、前記問題への対処法を指定するようユーザに依頼する指定依頼処理と、
     前記指定依頼処理の依頼に応じて前記ユーザにより指定された対処法を、前記問題に関連する、前記工場で収集された収集データにおける変化と対応付けてデータベースに登録するデータベース登録処理とをコンピュータに実行させるデータ処理プログラム。
    A specification request process for requesting the user to specify a method for dealing with the problem when a production problem occurs in the factory;
    A database registration process for registering a countermeasure specified by the user in response to the request for the designation request process in a database in association with a change in the collected data collected at the factory related to the problem. Data processing program to be executed.
PCT/JP2016/066938 2016-06-07 2016-06-07 Data processing device, data processing method, and data processing program WO2017212552A1 (en)

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