Analysis assistance device, analysis assistance method, and program

Abstract

To appropriately perform determination when abnormality occurs in a facility.SOLUTION: The analysis support device includes a collector configured to collect a maintenance record of the facility, an extractor configured to extract, from the maintenance record, maintenance information including operation information related to a handling operation when an abnormality occurs in the facility, a symptom of the abnormality of the facility, and a factor of the abnormality of the facility, an accumulator configured to accumulate the maintenance information, a creator configured to create an analysis dictionary in which at least one of the operation information and data related to the abnormality of the facility is associated with the symptom of the abnormality of the facility, an analyzer configured to analyze the factor of the abnormality of the facility based on at least one of the operation information and the monitoring data of the state of the facility acquired by the acquirer, and the analysis dictionary, and an outputter configured to output the analysis report.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to an analysis support device, an analysis support method, and a program. [Background technology]

[0002] The records of maintenance performed on equipment can be used for the next maintenance and its planning, and are utilized for managing the equipment. Patent Document 1 discloses a maintenance improvement support system that presents an appropriate maintenance improvement introduction plan based on the user's improvement policy. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-181230 Summary of the Invention [Problem to be solved by the invention]

[0004] In the past, when a customer or other user experienced an equipment abnormality in the past, the user dealt with the abnormality based on their own know-how. In factory automation (FA), multiple pieces of equipment are in operation, and equipment abnormalities vary widely, making it difficult to know which equipment manufacturer (equipment manufacturer) to contact and how to respond. Furthermore, even if a user contacted the equipment manufacturer, they often could not receive a prompt response unless they confirmed detailed information about the equipment, resulting in extended equipment downtime. As such, when an abnormality occurs in equipment, it is necessary to make an appropriate judgment, but the above-mentioned prior art does not allow for appropriate judgment when an abnormality occurs in equipment.

[0005] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a technique that enables appropriate judgment when an abnormality occurs in equipment. [Means for solving the problem]

[0006] An analysis support device according to one aspect of the present invention includes a collection unit that collects maintenance records of equipment, an extraction unit that extracts maintenance information from the maintenance records, including work information related to countermeasures when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment, a storage unit that stores the maintenance information, a creation unit that creates an analytical dictionary that links the work information, at least one of data related to the abnormality in the equipment, and the symptoms of the abnormality in the equipment, an analysis unit that analyzes the causes of the abnormality in the equipment based on the work information, at least one of monitoring data on the status of the equipment acquired by the acquisition unit, and the analytical dictionary, and creates an analysis report, and an output unit that outputs the analysis report. A user can check the analysis report to take immediate, provisional, or temporary measures against the abnormality in the equipment. This enables appropriate judgment when an abnormality occurs in the equipment.

[0007] The analysis support device includes an input unit that accepts input of the maintenance record from a user, and the input items of the maintenance record include at least the type of business, the name of the equipment, the name of the manufacturer of the equipment, and the error status of the equipment.

[0008] The analysis report is classified into either (1) equipment-related errors, (2) errors with multiple causes including the equipment-related errors, or (3) new errors that do not fall into either the equipment-related errors or the multiple-cause errors. By checking the analysis report, the user can recognize whether the cause of the equipment abnormality is an equipment-related error, a multiple-cause error, or a new cause. This allows the user to make better decisions when an abnormality occurs in the equipment. It is possible to do this more appropriately.

[0009] An analysis support device according to one aspect of the present invention includes a collection unit that collects maintenance records of equipment, an extraction unit that extracts maintenance information from the maintenance records, including work information related to countermeasures when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment, a storage unit that stores the maintenance information, an improvement proposal unit that creates an improvement report related to improvements in the maintenance of the equipment based on the maintenance information, and an output unit that outputs the improvement report. A user can take permanent measures to address the abnormality in the equipment by checking the improvement report. This enables appropriate judgment when an abnormality occurs in the equipment.

[0010] The analysis support device includes an input unit that accepts input of the maintenance record from a user, and the input items of the maintenance record include at least the type of business, the name of the equipment, the name of the manufacturer of the equipment, and the error status of the equipment.

[0011] The improvement proposal unit creates introduction information for introducing a consultant who will provide consulting on improving the facility, the introduction information including at least one of the consultant's area of ​​expertise and workload status, and the output unit outputs the introduction information. If the user is able to improve the facility, the improvement proposal unit creates the improvement report and the output unit outputs the improvement report. If the user is unable to improve the facility, the improvement proposal unit creates the introduction information and the output unit outputs the introduction information. The user can make an inquiry to a consultant based on the introduction information and request the consultant to improve the facility. The user can appropriately select a consultant by selecting at least one of a plurality of consultants based on at least one of the consultant's area of ​​expertise and workload status.

[0012] The improvement report is classified into one of the following categories: (1) errors caused by equipment factors, (2) errors caused by multiple factors including the equipment factors, or (3) new errors that do not fall into either the equipment factors or the multiple factors. By checking the improvement report, the user can recognize whether the cause of the equipment abnormality is an equipment factor, multiple factors, or new factor. This enables the user to more appropriately take permanent measures to address the equipment abnormality.

[0013] The present invention can be understood as an analysis support method including at least a part of the above-described processing, a program for causing a computer to execute at least a part of the above-described processing, or a computer-readable recording medium on which such a program is non-temporarily recorded. It can also be understood as an analysis support system including at least a part of the above-described processing. The above configurations and processing can be combined to constitute the present invention as long as no technical contradictions arise. [Effects of the Invention]

[0014] According to the present invention, it is possible to make an appropriate decision when an abnormality occurs in equipment. According to the present invention, it is possible to accumulate know-how on equipment maintenance and to make an immediate decision when an abnormality occurs in equipment, thereby improving the equipment's uptime (production efficiency). In addition, the burden on maintenance workers is reduced. Furthermore, unnecessary inquiries from users to equipment manufacturers are reduced, and equipment manufacturers can respond appropriately to equipment abnormalities, thereby reducing the burden on the equipment manufacturers. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a diagram showing the overall configuration of an analysis support system to which the present invention is applied. [Figure 2] FIG. 2 is a functional block diagram of the analysis support device. [Figure 3] FIG. 3 is a diagram showing an example of a maintenance record created in a dedicated file format. [Figure 4]FIG. 4 is a diagram illustrating an example of the storage unit. [Figure 5] FIG. 5 is a diagram illustrating an example of the analysis report. [Figure 6] FIG. 6 illustrates an example of the storage unit. [Figure 7] FIG. 7 is a diagram showing an example of input items for the maintenance record. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, application examples and embodiments will be described with reference to the drawings. The application examples and embodiments described below are aspects of the present application and do not limit the scope of the rights of the present application.

[0017] <Application example> FIG. 1 is a diagram showing the overall configuration of an analysis support system (maintenance system) to which the present invention is applied. The analysis support system includes an analysis support device 1, a control device 2, and one or more sensors 3. The analysis support device 1 is communicatively connected to the control device 2 via a wired or wireless connection. The analysis support device 1 is, for example, an IPC (Industrial Personal Computer). The control device 2 is communicatively connected to equipment 4 via a wired or wireless connection. The control device 2 is, for example, a PLC (Programmable Logic Controller), and controls the equipment 4. The equipment 4 is, for example, a production device, a processing device, etc., but is not limited to these. The control device 2 may be one or more. The equipment 4 may be one or more. The control device 2 is communicatively connected to one or more sensors 3 via wired or wireless communication. The one or more sensors 3 measure various parameters during operation of the equipment 4. The measurement values ​​measured by the one or more sensors 3 are sent to the control device 2. The analysis support device 1 acquires the measurement values ​​from the control device 2 as monitoring data for the state of the equipment 4. For example, if the measurement values ​​measured by the one or more sensors 3 exceed a threshold, the analysis support device 1 and the control device 2 detect an abnormality in the equipment 4. An abnormality in the equipment 4 is a state in which the equipment 4 is no longer normal.

[0018] One or more information processing devices 5 are communicatively connected to the analysis support device 1 wirelessly or via a wire. The information processing device 5 is, for example, a smartphone, a tablet terminal, a personal computer, or a smartwatch. When the analysis support device 1 detects an abnormality in the equipment 4, it sends a notification indicating that an abnormality has occurred in the equipment 4 to the information processing device 5. The user recognizes that an abnormality has occurred in the equipment 4 by checking the message in the notification. When an abnormality has occurred in the equipment 4, the user takes corrective action and creates a maintenance record for the equipment 4. The corrective action is an action to alleviate the symptoms of the abnormality in the equipment 4 and restore the equipment 4 to a temporary operable state or a normal state when an abnormality in the equipment 4 occurs. The symptoms of the equipment 4 are a state in which an abnormality in the equipment 4 becomes apparent and affects production, quality, and safety. Symptoms of an abnormality in equipment 4 include, but are not limited to, a high temperature at a specific location of equipment 4, worn parts of equipment 4, broken parts of equipment 4, deteriorated insulation in equipment 4, deteriorated or disconnected heaters in equipment 4, worn or damaged cutting tools in equipment 4, and abnormal current in equipment 4. Examples of symptoms of an abnormality in equipment 4 include, but are not limited to, an inability to obtain the output required for a conveyor to operate to a normal position, an inability to process an object due to worn cutting tools, vibration causing the precision of the processed surface to deviate from the standard value, poor welding due to insufficient welding output, a fire caused by excessive temperature rise, and electric shock due to leakage current. The user may create the maintenance record in a data file or on a paper form (paper medium). The maintenance record includes work information regarding the work to be done when an abnormality occurs in equipment 4, and maintenance information including the symptoms of the abnormality in equipment 4 and the causes of the abnormality in equipment 4.

[0019] The analysis support device 1 collects maintenance records and extracts maintenance information including work information on countermeasures to be taken when an abnormality occurs in the equipment 4, symptoms of the abnormality in the equipment 4, and causes of the abnormality in the equipment 4 from the maintenance records. The analysis support device 1 is provided with a database (storage unit) 6. The analysis support device 1 stores the maintenance information extracted from the maintenance records in the database 6. The analysis support device 1 creates an analysis dictionary that links at least one of the work information and data related to abnormalities in the equipment 4 with symptoms of the abnormality in the equipment 4 when an abnormality occurs in the equipment 4. The data related to the abnormality in the equipment 4 may be data related to measurement values ​​measured by one or more sensors 3.

[0020] The analysis support device 1 analyzes the cause of the abnormality in the equipment 4 based on at least one of the work information and the monitoring data and the analytical dictionary, and creates an analysis report. The analysis report is a report that allows the user to take immediate, provisional, or temporary measures in response to the abnormality in the equipment 4. The analysis support device 1 outputs the analysis report. The analysis support device 1 may output the analysis report by attaching it to an email or a chat, or may output the analysis report directly. The information processing device 5 receives the analysis report output from the analysis support device 1. The user checks the analysis report displayed on the screen of a display (display unit) in the information processing device 5. The analysis support device 1 may print and output the analysis report on a paper medium. By checking the analysis report, the user can take immediate, provisional, or temporary measures in response to the abnormality in the equipment 4. This makes it possible to make appropriate decisions when an abnormality occurs in the equipment 4.

[0021] The analysis support device 1 creates an improvement report regarding improvements to the maintenance of the equipment 4 based on the maintenance information. The improvement report is a report that allows the user to take permanent measures to address an abnormality in the equipment 4. The analysis support device 1 outputs the improvement report. The analysis support device 1 may output the improvement report by attaching it to an email or chat, or may directly output the analysis report. The information processing device 5 receives the improvement report output from the analysis support device 1. The user checks the improvement report displayed on the display screen of the information processing device 5. The analysis support device 1 may print and output the improvement report on paper media. By checking the improvement report, the user can take permanent measures to address an abnormality in the equipment 4. This makes it possible to make appropriate decisions when an abnormality occurs in the equipment 4.

[0022] <Description of the embodiment> The analysis support device 1 may be configured with dedicated equipment or a general-purpose computer. The analysis support device 1 includes hardware resources such as a processor, memory, and storage. The processor may be a general-purpose processor such as a CPU (Central Processing Unit) or an MPU (Micro Processing Unit), or may be a dedicated processor. The processor may be configured as a single circuit, or may be configured by combining multiple independent circuits. The memory may be RAM (Random Access Memory). The storage may be a non-volatile storage device such as ROM (Read Only Memory) or flash memory.

[0023] FIG. 2 is a functional block diagram of the analysis support device 1. The analysis support device 1 mainly comprises a collection unit 10, an extraction unit 11, an accumulation unit 12, an acquisition unit 13, a monitoring unit 14, a creation unit (first creation unit) 15, an analysis unit 16, an improvement proposal unit 17, an output unit 18, a memory unit 19, an input unit 20, and a maintenance record creation unit (second creation unit) 21. The functions of each processing unit (functional unit) of the analysis support device 1 are realized by expanding a program stored in a storage into a memory and executing it with a processor. Not all of the components of the analysis support device 1 shown in FIG. 2 are essential, and components of the analysis support device 1 may be added or deleted as appropriate. All or part of the functions of the analysis support device 1 may be implemented by an ASIC (Application Specific Integrated Circuit). Alternatively, all or part of the functions of analysis support device 1 may be executed by a cloud server or other device.

[0024] The collection unit 10 collects maintenance records of the equipment 4. The user may handwrite the maintenance records on a paper form (paper medium). For example, the user may write the maintenance records on the paper form, such as the type of industry, the name of the equipment 4, the name of the manufacturer of the equipment 4, the time when an abnormality occurred in the equipment 4, the error status of the equipment 4, the content of the countermeasure work, the start time of the countermeasure work, the end time of the countermeasure work, and the time required for the countermeasure work (response time). The error status of the equipment 4 includes symptoms of the equipment 4 when an abnormality occurs in the equipment 4 (symptoms of the abnormality in the equipment 4), causes of the abnormality in the equipment 4 when an abnormality occurs in the equipment 4 (causes of the abnormality in the equipment 4), etc. Without being limited to these examples, the maintenance records may also include the model, years of operation, and production item of the equipment 4, the name and cause of the malfunction in the equipment 4, repair parts, the name of the worker, years of experience, age, and years of maintenance work. The maintenance record may also include the company name, facility name, and process name of the equipment 4, the circumstances under which the abnormality occurred, specific symptoms of the abnormality, the cause of the abnormality, specific recovery work, the time required for recovery from the occurrence of the abnormality, the man-hours required for recovery from the occurrence of the abnormality (number of people x hours), repair costs, etc. The user may use a camera provided in the information processing device 5 to take a photo of the paper form on which the maintenance record is written. The information processing device 5 performs OCR (Optical Character Recognition) processing to convert the image data into The collection unit 10 may collect the maintenance records by acquiring the text data of the maintenance records from the information processing device 5.

[0025] The user may create a maintenance record in a general-purpose file format using a general-purpose application (e.g., a spreadsheet application) installed in the information processing device 5. For example, the user may use the general-purpose application to input maintenance records such as the type of business, the name of the equipment 4, the name of the manufacturer of the equipment 4, the time when an abnormality occurred in the equipment 4, the measurement value, the error status of the equipment 4, the content of the countermeasure work, the start time of the countermeasure work, the end time of the countermeasure work, and the time required for the countermeasure work (response time), thereby creating a general-purpose file having data of the maintenance record. The collection unit 10 may collect the maintenance records by acquiring a general-purpose file having data of the maintenance record from the information processing device 5.

[0026] The user may create a maintenance record in a dedicated file format using a dedicated application installed in the information processing device 5. For example, the user may use the dedicated application to input a maintenance record such as the name of the equipment 4, the name of the manufacturer of the equipment 4, the time when the abnormality occurred in the equipment 4, the measurement value, the error status of the equipment 4, the content of the response work, the time when the response work started, the time when the response work ended, and the time required for the response work (response time), thereby creating a dedicated file containing data of the maintenance record.

[0027] FIG. 3 is a diagram showing an example of a maintenance record created in a dedicated file format. In FIG. 3, a dedicated file is created containing maintenance record data such as the type of business, the name of the equipment 4, the name of the manufacturer of the equipment 4, the date and time when an abnormality occurred in the equipment 4, measurement values, the error status of the equipment 4, the content of the countermeasure work, the start time of the countermeasure work, the end time of the countermeasure work, and the time required for the countermeasure work (response time). In addition, photographic data of the equipment 4 when an abnormality occurred in the equipment 4, photographic data of the equipment 4 when the countermeasure work was performed, etc. may be attached to the maintenance record. The user attaches the photographic data to the maintenance record by taking a photograph using a camera provided in the information processing device 5. The dedicated application may automatically input the name of the equipment 4, the name of the manufacturer of the equipment 4, the date and time when the abnormality occurred in the equipment 4, and the measurement values ​​by acquiring the name of the equipment 4, the name of the manufacturer of the equipment 4, the date and time when the abnormality occurred in the equipment 4, and the measurement values ​​from the control device 2. The collection unit 10 may collect the maintenance records by acquiring a dedicated file containing the maintenance record data from the information processing device 5.

[0028] The extraction unit 11 extracts, from the maintenance record, maintenance information including work information related to countermeasure work when an abnormality occurs in the equipment 4, symptoms of the abnormality in the equipment 4, and causes of the abnormality in the equipment 4. The extraction unit 11 generates an extraction model by artificial intelligence (AI) or machine learning, and extracts the extracted information. The model may be used to extract maintenance information from maintenance records. The time information regarding the abnormality may include, but is not limited to, the stop time of the equipment 4, the time when the equipment 4 stopped operating, the time when the equipment 4 restarted operating, the time when the countermeasure work started, the time when the countermeasure work ended, the time required for the countermeasure work (response time), etc.

[0029] The storage unit 12 stores maintenance information. Fig. 4 is a diagram showing an example of the storage unit 12. The storage unit 12 has a plurality of individual company databases (DB) 30, an integrated database (DB) 31, and an equipment database (DB) 32. The plurality of individual company databases 30 store maintenance information for each individual company. The integrated database 31 stores all of the maintenance information in the plurality of individual company databases 30. The equipment database 32 stores maintenance information for each piece of equipment 4.

[0030] The acquisition unit 13 acquires monitoring data on the state of the equipment 4. The acquisition unit 13 acquires measurement values ​​measured by one or more sensors 3 as monitoring data on the state of the equipment 4. The monitoring unit 14 determines whether or not an abnormality has occurred in the equipment 4 based on the monitoring data. If the monitoring data satisfies a predetermined condition, the monitoring unit 14 detects an abnormality in the equipment 4. Examples of cases in which the monitoring data satisfies the predetermined condition are shown below, but are not limited to these examples.

[0031] The monitoring unit 14 may detect an abnormality in the equipment 4 when the measurement value exceeds a threshold value. The monitoring unit 14 may count the number of times the measurement value in a unit time exceeds a threshold value, and when the counted number is equal to or greater than a predetermined number, detect an abnormality in the equipment 4. The monitoring unit 14 may detect an abnormality in the equipment 4 when the measurement value is equal to or less than the threshold value. The monitoring unit 14 may count the number of times the measurement value in a unit time is equal to or less than the threshold value, and when the counted number is equal to or greater than a predetermined number, detect an abnormality in the equipment 4. When the monitoring unit 14 detects an abnormality in the equipment 4, it sends a notification to the information processing device 5 indicating that an abnormality has occurred in the equipment 4.

[0032] The creation unit 15 creates an analysis dictionary that links at least one of the work information and data related to an abnormality in the equipment 4 with symptoms of the abnormality in the equipment 4 when an abnormality occurs in the equipment 4. The data related to the abnormality in the equipment 4 may be data related to a measurement value when the measurement value exceeds a threshold. The threshold can be set for each user. The data related to the abnormality in the equipment 4 may also be data related to a measurement value when the measurement value is equal to or less than the threshold. The data related to the measurement value is, for example, but is not limited to, raw data of the measurement value, data indicating that the measurement value exceeds the threshold, data indicating that the measurement value is less than the threshold, or evaluation data when the measurement value is evaluated. The evaluation data is, for example, but is not limited to, the number of times the measurement value exceeds the threshold in a unit time or the number of times the measurement value is equal to or less than the threshold in a unit time.

[0033] The analysis unit 16 analyzes the cause of the abnormality in the equipment 4 based on at least one of the work information and the monitoring data acquired by the acquisition unit 13, and the analysis dictionary, and creates an analysis report. The analysis unit 16 may generate an analysis model using generative AI or machine learning, and create the analysis report using the analysis model. When the analysis report is created by the analysis unit 16, the output unit 18 outputs the analysis report.

[0034] FIG. 5 is a diagram showing an example of an analysis report. The balloon area Z1 shows the results of the analysis performed by the analysis unit 16. The area Z2 shown by the dotted rectangle displays multiple candidates estimated as the cause of the abnormality in the equipment 4, along with their ranking. In FIG. 5, the cause (misalignment) is selected, so the balloon area Z3 displays the number of maintenance records related to the cause (misalignment). When the cause (sealing jam) is selected, the balloon area Z3 displays the number of maintenance records related to the cause (sealing jam). When the cause (bearing grease shortage) is selected, the balloon area Z3 displays the number of maintenance records related to the cause (bearing grease shortage). Analysis Report A file of maintenance records related to the selected factor may be attached to the report. A plurality of files may be attached to the analysis report in descending order of relevance.

[0035] The analysis report may be classified into any of (1) equipment-caused errors, (2) multiple-caused errors including equipment-caused errors, or (3) new errors that do not fall into either equipment-caused errors or multiple-caused errors. Multiple causal factors include equipment factors and human factors, environmental factors, component factors, etc. other than equipment factors. If the cause of the abnormality in the equipment 4 is an equipment factor, the analysis unit 16 creates an analysis report classified as an equipment-caused error. If the cause of the abnormality in the equipment 4 is multiple factors, the analysis unit 16 creates an analysis report classified as an error with multiple causes. If the cause of the abnormality in the equipment 4 is a new factor, the analysis unit 16 creates an analysis report classified as an error with a new cause. A new factor is a factor that does not fall into either equipment factors or multiple causes.

[0036] By checking the analysis report, the user can recognize whether the cause of the abnormality in the equipment 4 is an equipment factor, a combination of factors, or a new factor. This allows the user to make a more appropriate decision when an abnormality occurs in the equipment 4. If the cause of the abnormality in the equipment 4 is an equipment factor, the user can discover the cause of the abnormality in the equipment 4 in a short period of time by investigating the cause of the abnormality in the equipment 4 presented in the analysis report. Furthermore, if the cause of the abnormality in the equipment 4 is an equipment factor, the user may make an inquiry to the equipment manufacturer based on the monitoring data (measurement values) of the equipment 4's status. If the cause of the abnormality in the equipment 4 is a combination of factors, the user can discover the cause of the abnormality in the equipment 4 in a short period of time by investigating the cause of the abnormality in the equipment 4 presented in the analysis report and also human factors, environmental factors, component factors, etc. Furthermore, if the cause of the abnormality in the equipment 4 is a combination of factors, the user may make an inquiry to the equipment manufacturer based on the monitoring data (measurement values) of the equipment 4's status. If the cause of the abnormality in the equipment 4 is a new factor, the user may request a third party to investigate.

[0037] The improvement proposing unit 17 creates an improvement report regarding improvements to the maintenance of the equipment 4 based on the maintenance information. The contents of the improvement report may be displayed using at least one of a Pareto chart, a cause-and-effect diagram, a graph, a histogram, a scatter diagram, a control chart, and a checklist. The improvement proposing unit 17 may generate an improvement proposal model using a generation AI or machine learning, and create the improvement report using the improvement proposal model. When the improvement report is created by the improvement proposing unit 17, the output unit 18 outputs the improvement report.

[0038] The improvement report may be classified into any of (1) equipment-related errors, (2) multiple-cause errors including equipment-related errors, or (3) new errors that do not fall into either equipment-related errors or multiple-cause errors. If the cause of the abnormality in the equipment 4 is an equipment-related error, the improvement proposing unit 17 creates an improvement report classified as an equipment-related error. If the cause of the abnormality in the equipment 4 is multiple-cause errors including equipment-related errors, the improvement proposing unit 17 creates an improvement report classified as an error of multiple causes. If the cause of the abnormality in the equipment 4 is a new cause, the improvement proposing unit 17 creates an improvement report classified as an error of a new cause.

[0039] By checking the improvement report, the user can recognize whether the cause of the abnormality in equipment 4 is an equipment factor, a complex factor, or a new factor. This enables the user to more appropriately take permanent measures to address the abnormality in equipment 4. If the cause of the abnormality in equipment 4 is an equipment factor, the user may take permanent measures to address the abnormality in equipment 4 based on the contents of the improvement report. Also, if the cause of the abnormality in equipment 4 is an equipment factor, the user may make an inquiry to the equipment manufacturer based on monitoring data (measurement values) of the status of equipment 4. If the cause of the abnormality in equipment 4 is a complex factor, the user may take permanent measures to address the abnormality in equipment 4 based on the contents of the improvement report, and may also take permanent measures to address human factors, environmental factors, component factors, etc. Also, if the cause of the abnormality in equipment 4 is a complex factor, the user may take permanent measures to address the abnormality in equipment 4 based on the contents of the improvement report. If this is the case, the user may make an inquiry to the equipment manufacturer based on the monitoring data (measurement values) of the state of the equipment 4. If the cause of the abnormality in the equipment 4 is a new cause, the user may request a third party to investigate.

[0040] The improvement proposal unit 17 creates introduction information for introducing a consultant (improvement consultant) who will provide consulting on improving the facility 4, the introduction information including at least one of the consultant's area of ​​expertise and workload status. When the introduction information is created by the improvement proposal unit 17, the output unit 18 outputs the introduction information. The introduction information may include information on multiple consultants. If the user is able to improve the facility 4, the improvement proposal unit 17 creates an improvement report, and the output unit 18 outputs the improvement report. If the user is unable to improve the facility 4, the improvement proposal unit 17 creates introduction information, and the output unit 18 outputs the introduction information. This enables the user to make an inquiry to a consultant based on the introduction information and request the consultant to improve the facility 4.

[0041] The referral information includes at least one of the consultant's specialty and workload status. The user may select at least one of multiple consultants based on at least one of the consultant's specialty and workload status. For example, the user can select a consultant who is skilled in the electrical field or a consultant who is skilled in the mechanical field. This allows the user to appropriately select a consultant. In this way, it is possible to place and receive orders for consulting services for improving facility 4 based on at least one of the consultant's specialty and workload status.

[0042] The storage unit 19 stores various types of data and information. FIG. 6 is a diagram showing an example of the storage unit 19. The storage unit 19 has a consultant information database 40. The consultant information database 40 stores information about consultants' areas of expertise and information about the workload status of the consultants. The information about consultants' areas of expertise and information about the workload status of the consultants in the consultant information database 40 is updated as needed.

[0043] The input unit 20 accepts maintenance record input from a user. FIG. 7 is a diagram showing an example of maintenance record input items. The maintenance record input items include at least "industry type," "equipment name," "equipment manufacturer name," and "equipment error status." Furthermore, the maintenance record input items include "time of equipment abnormality occurrence," "measurement value," "details of countermeasure work," "start time of countermeasure work," "end time of target work," and "response time." The maintenance record input items are not limited to these and may include other items. The maintenance record input items may include the model, years of operation, and production item of the equipment 4, the name and cause of the equipment 4 malfunction, repair parts, the worker's name, years of experience, age, and years of maintenance work. The maintenance record input items may also include the company name, facility name, and process name of the equipment 4, the occurrence status of the malfunction, specific symptoms of the malfunction, the cause of the malfunction, specific recovery work, the time required for recovery from the occurrence of the malfunction, the labor hours (number of people x hours) required for recovery from the occurrence of the malfunction, and repair costs. For example, input items for the maintenance record may be displayed on the display screen of the information processing device 5, and the user may use the information processing device 5 to input data according to the input items of the maintenance record. The input unit 20 or a dedicated application installed on the information processing device 5 may acquire information and data relating to each of the input items, "name of the equipment," "name of the equipment manufacturer," "time when the equipment abnormality occurred," and "measured value," from the control device 2. In this case, information and data relating to these input items are pre-entered into each of the input items, "name of the equipment manufacturer," "time when the equipment abnormality occurred," and "measured value," on the display screen of the information processing device 5. This simplifies the user's input work.

[0044] In addition, input items for the maintenance record may include work procedures and tools. Tools may be selectable. For example, multiple tools may be displayed on the display screen of the information processing device 5, and the user may select at least one of the multiple tools. In addition, the input unit 20 may accept input of photo data, drawing data, video data, etc. from the user. When the input unit 20 accepts input of a maintenance record from the user, the maintenance record creation unit 21 creates a maintenance record in a dedicated file format. When the input unit 20 accepts input of photo data, drawing data, video data, manuals, etc. from the user, the photo data, drawing data, video data, manuals, etc. are attached to the maintenance record in the dedicated file format. The user may take a photo using a camera provided in the information processing device 5, and the photo data may be attached to the maintenance record in the dedicated file format.

[0045] The analysis support system makes it possible to accumulate know-how on the maintenance of FA equipment and to make instant decisions when an abnormality occurs in the FA equipment, thereby improving the uptime (production efficiency) of the FA equipment. The analysis support system also makes it possible to take permanent measures to address abnormalities in the FA equipment in a short period of time, thereby improving the uptime (production efficiency) of the FA equipment. It also reduces the burden on maintenance workers. Furthermore, it reduces unnecessary inquiries from users to equipment manufacturers and allows equipment manufacturers to respond appropriately to abnormalities in the FA equipment, thereby reducing the burden on the equipment manufacturers.

[0046] The present invention can also be understood as a monitoring method including at least a part of the above-described processing, a program for causing a computer to execute at least a part of the above-described processing, or a computer-readable recording medium on which such a program is non-temporarily recorded. It can also be understood as a monitoring system including at least a part of the above-described processing. The above configurations and processing can be combined to constitute the present invention as long as no technical contradictions arise.

[0047] <Appendix 1> a collection unit (10) for collecting maintenance records of the equipment (4); an extraction unit (11) that extracts, from the maintenance record, maintenance information including work information related to countermeasure work when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage unit (12) that stores the security information; a creation unit (15) that creates an analysis dictionary that links at least one of the work information and data related to abnormalities in the equipment (4) with symptoms of the abnormalities in the equipment (4); an analysis unit (16) that analyzes causes of abnormalities in the equipment (4) based on at least one of the work information and monitoring data on the state of the equipment (4) acquired by the acquisition unit (13) and the analysis dictionary, and creates an analysis report; an output unit (18) that outputs the analysis report; An analysis support device (1) comprising: <Appendix 2> an input unit (20) for receiving input of the maintenance record from a user; The input items of the maintenance record include at least the type of business, the name of the equipment (4), the manufacturer name of the equipment (4), and the error status of the equipment (4). An analysis support device (1) according to appendix 1. <Appendix 3> The analysis report is classified into either (1) an error caused by an equipment factor, (2) an error caused by multiple factors including the equipment factor, or (3) a new error that does not fall into either the error caused by an equipment factor or the error caused by multiple factors. An analysis support device (1) according to appendix 1 or 2. <Appendix 4> a collection unit (10) for collecting maintenance records of the equipment (4); an extraction unit (11) that extracts, from the maintenance record, maintenance information including work information related to countermeasure work when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage unit (12) that stores the security information; an improvement suggestion unit (17) that creates an improvement report regarding improvements to the maintenance of the facility (4) based on the maintenance information; an output unit (18) that outputs the improvement report; An analysis support device (1) comprising: <Appendix 5> an input unit (20) for receiving input of the maintenance record from a user; The input items of the maintenance record include at least the type of business, the name of the equipment (4), the manufacturer name of the equipment (4), and the error status of the equipment (4). An analysis support device (1) according to appendix 4. <Appendix 6> the improvement proposal unit (17) creates introduction information for introducing a consultant who will provide consulting on the improvement of the facility (4), the introduction information including at least one of the consultant's specialty area and workload status; The output unit (18) outputs the introduction information. An analysis support device (1) according to appendix 4 or 5. <Appendix 7> If the facility (4) can be improved by the user, the improvement suggestion unit (17) creates the improvement report, and the output unit (18) outputs the improvement report. If the user is unable to improve the facility (4), the improvement suggestion unit (17) creates the recommendation information, and the output unit (18) outputs the recommendation information. An analysis support device (1) according to appendix 6. <Appendix 8> The improvement report is classified into one of (1) errors caused by equipment factors, (2) errors caused by multiple factors including the equipment factors, or (3) new errors that do not fall into either the equipment factors or the multiple factors. An analysis support device (1) according to any one of appendices 4 to 7. <Appendix 9> The computer collecting maintenance records of the equipment (4); an extraction step of extracting, from the maintenance record, maintenance information including work information related to countermeasure work when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage step of storing the security information in a storage unit (12); a creation step of creating an analysis dictionary linking at least one of the work information and data related to abnormalities in the equipment (4) with symptoms of the abnormalities in the equipment (4); an analysis step of analyzing causes of abnormalities in the equipment (4) based on at least one of the work information and monitoring data on the state of the equipment (4) acquired by the acquisition unit (12) and the analysis dictionary, and creating an analysis report; an output step of outputting the analysis report; An analytical support method for performing the above. <Appendix 10> The computer collecting maintenance records of the equipment (4); an extraction step of extracting, from the maintenance record, maintenance information including work information related to countermeasure work when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage step of storing the security information in a storage unit (12); an improvement proposal step of creating an improvement report regarding improvements to the maintenance of the facility (4) based on the maintenance information; an output step of outputting the improvement report; An analytical support method for performing the above. <Appendix 11> On the computer, collecting maintenance records of the equipment (4); an extraction step of extracting, from the maintenance record, maintenance information including work information related to countermeasure work when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage step of storing the security information in a storage unit (12); a creation step of creating an analysis dictionary linking at least one of the work information and data related to abnormalities in the equipment (4) with symptoms of the abnormalities in the equipment (4); an analysis step of analyzing causes of abnormalities in the equipment (4) based on at least one of the work information and monitoring data on the state of the equipment (4) acquired by the acquisition unit (12) and the analysis dictionary, and creating an analysis report; an output step of outputting the analysis report; A program to execute. <Appendix 12> On the computer, collecting maintenance records of the equipment (4); an extraction step of extracting, from the maintenance record, maintenance information including work information related to countermeasure work when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage step of storing the security information in a storage unit (12); an improvement proposal step of creating an improvement report regarding improvements to the maintenance of the facility (4) based on the maintenance information; an output step of outputting the improvement report; A program to execute. [Explanation of symbols]

[0048] 1:Analysis support equipment 2: Control device 3: Sensor 4: Equipment 5: Information processing device 6: Database 10: Collection Department 11:Extraction part 12: Storage section 13: Acquisition part 14: Monitoring Department 15: Creation Department 16:Analysis Department 17: Improvement proposal department 18: Output section 19: Storage section 20: Input section 21: Maintenance Records Creation Department 30: Individual company database 31: Integrated database 32: Facility database 40: Consultant information database

Claims

1. a collection department that collects maintenance records of the equipment; an extraction unit that extracts, from the maintenance record, maintenance information including work information related to a countermeasure work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage unit that stores the security information; a creation unit that creates an analysis dictionary that links at least one of the work information and the data related to the equipment abnormality with a symptom of the equipment abnormality; an analysis unit that analyzes causes of abnormalities in the equipment based on at least one of the work information and the monitoring data of the equipment status acquired by the acquisition unit, and the analysis dictionary, and creates an analysis report; an output unit that outputs the analysis report; An analysis support device comprising:

2. an input unit that accepts input of the maintenance record from a user; The input items of the maintenance record include at least the type of business, the name of the equipment, the name of the manufacturer of the equipment, and the error status of the equipment. The analysis support device according to claim 1 .

3. The analysis report is classified into any one of (1) errors caused by equipment factors, (2) errors caused by multiple factors including the equipment factors, or (3) new errors that do not fall into either the equipment factors or the multiple factors. The analysis support device according to claim 1 or 2.

4. a collection department that collects maintenance records of the equipment; an extraction unit that extracts, from the maintenance record, maintenance information including work information related to a countermeasure work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage unit that stores the security information; an improvement proposal unit that creates an improvement report regarding improvements to the maintenance of the facility based on the maintenance information; an output unit that outputs the improvement report; An analysis support device comprising:

5. an input unit that accepts input of the maintenance record from a user; The input items of the maintenance record include at least the type of business, the name of the equipment, the name of the manufacturer of the equipment, and the error status of the equipment. The analysis support device according to claim 4.

6. the improvement proposal unit creates introduction information for introducing a consultant who will provide consulting on the improvement of the facility, the introduction information including at least one of the consultant's specialty area and workload status; The output unit outputs the introduction information. The analysis support device according to claim 4.

7. If the facility can be improved by the user, the improvement suggestion unit creates the improvement report, and the output unit outputs the improvement report; If the user is unable to improve the facility, the improvement suggestion unit creates the recommendation information, and the output unit outputs the recommendation information. The analysis support device according to claim 6.

8. The improvement report is classified into one of (1) an error caused by an equipment factor, (2) an error caused by multiple factors including the equipment factor, or (3) a new error that does not fall into either the error caused by an equipment factor or the error caused by multiple factors. The analysis support device according to any one of claims 4 to 7.

9. The computer collecting maintenance records for the facility; an extraction step of extracting, from the maintenance record, maintenance information including work information related to a countermeasure work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage step of storing the security information in a storage unit; a creation step of creating an analytical dictionary linking at least one of the work information and the data related to the abnormality of the equipment with symptoms of the abnormality of the equipment; an analysis step of analyzing causes of abnormalities in the equipment based on at least one of the work information and the monitoring data of the equipment status acquired by the acquisition unit, and the analysis dictionary, and creating an analysis report; an output step of outputting the analysis report; An analytical support method for performing the above.

10. The computer collecting maintenance records for the facility; an extraction step of extracting, from the maintenance record, maintenance information including work information related to a countermeasure work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage step of storing the security information in a storage unit; an improvement proposal step of creating an improvement report regarding improvements to the maintenance of the facility based on the maintenance information; an output step of outputting the improvement report; An analytical support method for performing the above.

11. On the computer, collecting maintenance records for the facility; an extraction step of extracting, from the maintenance record, maintenance information including work information related to a countermeasure work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage step of storing the security information in a storage unit; a creation step of creating an analytical dictionary linking at least one of the work information and the data related to the abnormality of the equipment with symptoms of the abnormality of the equipment; an analysis step of analyzing causes of abnormalities in the equipment based on at least one of the work information and the monitoring data of the equipment status acquired by the acquisition unit, and the analysis dictionary, and creating an analysis report; an output step of outputting the analysis report; A program to execute.

12. On the computer, collecting maintenance records for the facility; an extraction step of extracting, from the maintenance record, maintenance information including work information related to a countermeasure work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage step of storing the security information in a storage unit; an improvement proposal step of creating an improvement report regarding improvements to the maintenance of the facility based on the maintenance information; an output step of outputting the improvement report; A program to execute.

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