Production support system and production support method

Abstract

To provide a production support system which supports a work or a decision of a worker with less work experience.SOLUTION: A production support system has: an industrial machine; storage means for storing past operation information of the industrial machine; detection means for detecting a step-in area of a worker performing a work related to the industrial machine and an action of the worker; and worker support means for supporting a decision on the work of the worker. The detection means detects that the worker is difficult to decide an action to be performed next in the area. The worker support means specifies the past operation information that is the same as or similar to current operation information in which the industrial machine operates when the worker is in the difficult state, specifies a work recommended for the worker to perform based on the specified past operation information, and displays the recommended work on display means.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a production support system and a production support method. [Background technology]

[0002] Patent Document 1 (JP Patent Publication No. 2010-257296) states that "the presence or absence of work carried into the equipment is detected by the presence sensor 5, and the presence sensor 7 detects the presence of a worker at each piece of equipment. The sequence controller 2 writes this information into the database of the server 8 as equipment operation information and worker presence information. A client terminal 10 connected to the server 8 via a LAN 9 associates the equipment with the worker using a worker registration table pre-registered in the database of the server 8, and combines this associated equipment operation information and worker presence information to display as a man-machine chart" (see abstract). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2010-257296 A Summary of the Invention [Problem to be solved by the invention]

[0004] Patent Document 1 discloses a technology for providing a production improvement support system that can grasp the operation status of equipment and the work status of a worker in conjunction with each other, even if the worker is responsible for multiple pieces of equipment. Regarding the worker's movements, a pressure sensor is placed under the mat to measure the time the worker is on the mat, thereby detecting which piece of equipment the worker was involved in. In addition, the type of work and equipment operation that the worker will perform is registered in advance in a worker registration table in association with the time and the equipment.

[0005] In other words, the system instructs operators on the operations and actions they should take in advance in response to the status of the equipment they are responsible for, such as stopped, waiting, in operation, changeover, and error, but does not take into account how operators should deal with equipment statuses that are not registered in this way.

[0006] In other words, when an operator with little work experience encounters an operation or situation for which the equipment has not been registered in advance, the operator may be unable to determine, or find it difficult to determine, what operation or behavior to perform.

[0007] In this case, the equipment managed by workers with little work experience may not be able to produce according to the production plan, and the equipment may not be able to operate until the judgment and assistance of workers with more work experience is obtained, which may result in a decrease in the productivity of the production system.

[0008] The present invention aims to provide a production support system and production support method that detects a state in which a worker with little work experience is unable to judge what action or task he or she should perform with respect to the equipment he or she is in charge of, and supports the worker's work or judgment by presenting the worker with a way to respond by referring to past cases. [Means for solving the problem]

[0009] A preferred example of the production support system of the present invention is a production support system having industrial equipment, a storage means for storing past operation information of the industrial equipment, an area for workers to enter who perform work related to the industrial equipment, a detection means for detecting the actions of the worker, and a worker support means for supporting the worker in making decisions about the work, wherein the detection means detects that the worker is in a difficult state in deciding what action to take next within the area, and the worker support means identifies the past operation information that is identical or similar to current operation information in which the industrial equipment is operating when the worker is in a difficult state, identifies work that is recommended for the worker to perform based on the identified past operation information, and displays the recommended work on a display means.

[0010] As another feature of the present invention, in the production support system, the worker support means reads from a database that stores in a storage means recorded information on response methods used in the past for past cases in which the past operation information of the industrial equipment is highly similar to the current operation information, and displays a list of response methods used in the past in order of most similar past cases on the input / output means used by the worker, and accepts the worker's selection.

[0011] Moreover, in a preferred example of the production support method of the present invention, the method includes the steps of: an image acquisition means acquires image data of a worker to be supported at every predetermined cycle time; a detection means extracts features representing the working state of the worker from the acquired image data and operation information of industrial equipment, and based on the features representing the working state of the worker obtained in time series, recognizes that the state of the industrial equipment in the hands of the worker is different from a normal state and identifies a state in which the worker is having difficulty dealing with the state; a worker support means acquires operation information of the industrial equipment in accordance with the identification of a state in which the worker is having difficulty dealing with the state; and a worker support means searches a database for past operation information of the corresponding industrial equipment that corresponds to the acquired current operation information of the industrial equipment, calculates the similarity between the two pieces of operation information, reads out information on past response methods for past operation information of the corresponding industrial equipment that is highly similar, and presents candidates for recommended response methods to the worker. Effect of the Invention

[0012] The production support device of the present invention can improve the productivity of a production system by supporting the work or judgment of workers who do not have much work experience and thereby increasing the operating rate of industrial equipment. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is an image diagram showing a production support device of the present invention being introduced into a production system. [Diagram 2] FIG. 1 is a diagram showing an example of a system block diagram of a production system according to the present invention. [Diagram 3]FIG. 2 is a diagram showing an example of a database stored in the production system of the present invention. [Figure 4] FIG. 4 is a diagram showing an example of a user interface displayed on an input / output unit of the production system of the present invention. [Diagram 5] 13 is a flowchart of a process for supporting a worker in charge of a support target. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] In recent years, the labor force has decreased, and the workload of each worker has increased. There are also more decisions to make, and it may be difficult to consult with superiors. In these circumstances, workers may feel anxious about their workplace due to their daily work. Workers working under these circumstances are likely to have a higher turnover rate due to a decrease in engagement, and the fixed costs of hiring new workers, training them after hiring, or retaining them are expected to increase.

[0015] Therefore, in the future industrial world where the labor force will decrease, in order to effectively reduce the increase in fixed costs mentioned above and improve productivity, it will be necessary to allow workers working within the production system to gain work experience and quickly increase their work proficiency, to have workers with more experience support workers with less work experience, or to provide a work environment that motivates workers as they gain more work experience and does not want to quit or change jobs.

[0016] The present invention can provide a production system that contributes to efficiently increasing the work experience of workers, quickly improving their work proficiency, and improving the engagement of workers with extensive work experience.

[0017] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0018] In the following description, information that gives an output for an input may be described using expressions such as "xxx table," but the information may be data of any structure (for example, structured data or unstructured data) or a learning model such as a neural network that generates an output for an input. Therefore, an "xxx table" may be referred to as "xxx information." In the following description, the structure of each table is an example, and one table may be divided into two or more tables, or all or part of two or more tables may be one table. EXAMPLES

[0019] FIG. 1 shows an image diagram of a production system 100 in which a production support device 200 according to this embodiment is introduced. The production system 100 has industrial equipment 110a, 110b, 110c, and 110d, and predetermined processing is performed on a workpiece 120 to be processed by 110a to 110d. The processed workpiece 120 is transported to the next industrial equipment by a responsible worker 130 or a transport means 140. The responsible worker 130 is a worker who performs work under the instructions of a senior worker (not shown) who has a lot of experience, is highly skilled, and / or can make high-level judgments. In this embodiment, the term may be simply referred to as a worker.

[0020] The industrial equipment 110a etc. are also called machine tools, and may be, for example, milling machines, lathes, drilling machines, etc. that perform metal processing, or injection molding machines, additive manufacturing machines such as resin or metal processing machines that perform additive manufacturing such as layered modeling, etc. An example of the conveying means 140 may be a material handling robot or an AVG (Automatic Guided Vehicle). The workpiece 120 is also called a member 120 or a processed object 120.

[0021] The worker in charge 130 performs the necessary work on the industrial equipment 110a to 110d according to the work procedure manual displayed on the input / output means 250a. For example, the worker in charge 130 performs the work required for the industrial equipment 110a to 110d, such as changing tools, jigs, or cutting oil for the industrial equipment 110a, transporting, mounting, and removing the workpiece 120, removing chips, swarf, supporting material, and unwelded powder or waste material generated by the additive manufacturing process, and performing maintenance on the industrial equipment 110a, etc.

[0022] The imaging device 150 is arranged so as to be movable or disposed so that the worker in charge 130 and the industrial equipment 110a to 110d are included in the angle of view. The imaging device 150 may be installed in correspondence with each industrial equipment or in a plurality of units as necessary so that the working area of ​​the worker in charge can be included in the field of view. The imaging device 150 is used to check the positional relationship between the worker in charge 130 and the industrial equipment 110a, etc., and the motion of the worker in charge 130. The imaging device 150 has a microphone and can acquire sounds emitted from the worker in charge 130 and the industrial equipment 110a, etc. In this embodiment, a method using the imaging device 150 will be described as a representative example, but the present invention can also be implemented in cases where the motion of the worker in charge 130 is measured using a wearable sensor worn by the worker in charge 130, a gyro sensor or an acceleration sensor of a terminal such as a smartphone owned by the worker in charge 130, or other sensors such as LIDAR (Light Detection and Ranging, Laser Imaging Detection and Ranging), a laser range finder, etc.

[0023] The production support device 200 inputs image data from the imaging device 150, processes the image, and determines the position of the worker in charge 130 and whether the worker in charge 130 is performing normal work or is having difficulty dealing with an unusual situation. If it is determined that the worker in charge 130 is having difficulty dealing with an unusual situation (anxious or confused), it searches a database for past status values ​​similar to the status values ​​of the industrial equipment in question and their response history information, and displays them on the input / output means 250a to support the worker in charge 130.

[0024] The production support device 200 normally displays on the input / output means 250a the work procedure manual or work instructions that are the next task to be performed by the worker in charge 130. If necessary, a senior worker can set or instruct the task of the worker in charge 130.

[0025] FIG. 2 is a configuration diagram of a production support device 200 according to this embodiment. The production support device 200 can be configured on a general-purpose computer, and its hardware configuration includes a control unit 210 configured with a CPU (Central Processing Unit), a RAM (Random Access Memory), etc., a storage unit 220 configured with a ROM (Read Only Memory), a HDD (Hard Disk Drive), an SSD (Solid State Drive) using a flash memory, etc., a communication unit 230 configured with a NIC (Network Interface Card), etc. Some of the functions of the production support device 200 can also be shared and implemented by an edge terminal and a server. The communication unit 230 is connected to a host manufacturing execution system 240 , industrial equipment 110 a and the like, input / output means 250 a and the like, and the imaging device 150 via a network 260 .

[0026] The control unit 210 realizes the following functional units by loading a production support program 221 stored in the storage unit 220 into the RAM and executing it with the CPU. The control unit 210 has a production plan acquisition unit 211, an image acquisition unit 212, an industrial equipment status value acquisition unit 213, an image processing unit 214, a worker support unit 215, an image learning unit 216, and an abnormal sound detection unit 217.

[0027] The production plan acquisition unit 211 acquires data on the production plan, work procedure manual, and work instruction manual from the host manufacturing execution system 240 in advance of the production date and time, and stores the data in the production plan 222, work procedure manual, and instruction manual 227 in the storage unit 220.

[0028] When the support target worker 130 is working, the image acquisition unit 212 acquires image data from an imaging device that has the support target worker in its field of view at every predetermined cycle. When there are multiple support target workers 130, image data that has each support target worker in its field of view is acquired at every predetermined cycle.

[0029] The industrial equipment status value acquisition unit 213 acquires operation information of all connected industrial equipment 110a, etc., such as status modes such as stopped, waiting, working, changeover, and error, from each industrial equipment periodically or when the status mode changes, and stores the information in the industrial equipment status value 223 of the storage unit 220. The operation information is not limited to these states, and information such as the G code with which the target industrial machine operates can also be used. Furthermore, when it is determined that the responsible worker is having difficulty dealing with the status of the industrial equipment through image processing by the responsible worker, the status value of the relevant industrial equipment (values ​​of each sensor installed in the industrial equipment) is acquired and stored in the industrial equipment status value 223 of the storage unit 220. However, the industrial equipment status value acquisition unit 213 may acquire the status value of the relevant industrial equipment as appropriate. For example, if it is determined that a responsible worker is in trouble, by tracing the status values ​​of the industrial equipment in chronological order from the status values ​​of the industrial equipment at a specified time before the determination is made to the time the determination is made, it is possible to seek the judgment of a senior worker who will separately explain what is happening to the industrial equipment, or to identify more appropriate actions or tasks that the worker should perform on the industrial equipment.

[0030] The image processing unit 214 inputs the image data acquired by the image acquisition unit 212, and also inputs the operation information (status mode) of the industrial equipment for which the worker in charge is in charge, and outputs a feature quantity that represents the working status of the worker in charge. Then, based on the time-series data of the feature quantity of the worker in charge, the image processing unit 214 recognizes that the status of the industrial equipment for which the worker in charge is in charge is different from the normal status and judges whether the worker in charge is having difficulty dealing with it, using a method to be described later.

[0031] The worker support unit 215 normally reads out the work procedure manual and instructions 227 in accordance with the production plan 222 and displays the work procedure manual and work instructions on the input / output means 250a or the like that is referenced by the worker in charge 130. When the image processing unit 214 judges that the worker in charge is having difficulty dealing with the state of the industrial equipment he is in charge of, the worker support unit 215 acquires the state value of the industrial equipment, compares it with the past state value of the industrial equipment stored in the industrial equipment response history 224 of the storage unit 220, and searches for a similar record. The past response history recorded in the similar record is displayed on the input / output means 250a or the like for the worker in charge's reference, thereby providing support.

[0032] The image learning unit 216 and the image processing unit 214 perform learning on predetermined image data. Learning is performed by capturing images of normal work actions, movement actions, setup changeover work, maintenance work, actions to check for abnormalities, etc. of a learning worker, and learning is performed using the image data at that time as explanatory variables and the actions as objective variables as input data. The hyperparameters of the classifier and learning device obtained by learning are stored in the image feature extraction parameters 225. In addition, the operation information of the industrial equipment can be used as learning data for the objective variables. Note that while supervised learning has been described above, it is also possible to learn difficult situations that are different from normal work by acquiring the actions of the worker in charge at the actual work site as unsupervised learning.

[0033] The abnormal sound detection unit 217 detects sounds input from a microphone attached to the imaging device 150, and uses the detection results to help the image processing unit 214 determine whether the worker in charge is having difficulty dealing with the condition of the industrial equipment he or she is in charge of.

[0034] The storage unit 220 has storage areas for a production support program 221, a production plan 222, industrial equipment status values ​​223, industrial equipment response history 224, parameters for image feature extraction 225, worker information 226, and a work procedure manual and instruction manual 227.

[0035] 3 shows an example of a data table stored in the industrial equipment response history 224 of the storage unit 220. The industrial equipment response history 224 constitutes a database that records the history of what response methods were taken in the past when some kind of response was required for industrial equipment (a situation in which the worker in charge had difficulty responding, and is not necessarily an error).

[0036] The columns of the data table of the industrial equipment response history 224 store industrial equipment name 224a, equipment status name 224b, features 224c, past response methods 224d, and worker name 224e. For example, in the data table example of Fig. 3, A1 to A4, which indicate the contents of failures or troubles that occurred in the past for industrial equipment A that required some kind of response, are stored in the equipment status name 224b column. The features 224c store the status values ​​of the industrial equipment, such as the cause of an error or a value acquired by a sensor, corresponding to the equipment status name (usually multiple status values ​​are stored).

[0037] In addition, the column of past response methods 224d lists the names of response methods, and the names of response methods are linked to information on past response content and work procedure content, and a data table of response content stored in the industrial equipment response history 224 can be called up.

[0038] Next, the name and code of the worker who performed the past response described above are entered in the column of worker name 224e. In addition, it is preferable to link the work department and contact information and store them in the industrial equipment response history 224.

[0039] An example of an interface for supporting the worker 130 in question about how to deal with the industrial equipment is shown and will be described in Fig. 4. An example of a screen for supporting the worker shown in the input / output means 250a used by the worker in question shown in Fig. 2 is a screen 250c. A similar equipment status display screen 410, a recommended response method display screen 420, and a call display screen 430 are displayed on the screen 250c.

[0040] The similar equipment status display screen 410 displays the equipment status name, past response methods, and worker names from the columns of the data table of the industrial equipment response history 224. Furthermore, the similarity indicates the degree of similarity between the status value of the industrial equipment stored in the feature 224c of the data table of the industrial equipment response history 224 and the status value of the industrial equipment indicating the current state or operating status of the fault or trouble that has occurred in the industrial equipment, acquired by the industrial equipment status value acquisition unit 213. The higher this degree, the more similar the status of the industrial equipment is, and therefore the past response is considered to be effective. Therefore, it is possible to deal with the industrial equipment more appropriately by trying a response method with a high similarity or contacting a worker who has dealt with the past. An example of a method for calculating the similarity will be described later.

[0041] The call display screen 430 shows that the target industrial equipment is 85% similar to the past equipment status name A1, so a call is being made to a senior worker XXA who has more experience dealing with equipment status name A1 in the past than the worker in charge.

[0042] When a worker in charge detects a difficult situation, the worker can directly contact a superior worker to prevent the worker from waiting in a difficult situation and to encourage a quick response. Even if the superior worker is not near the worker, the superior worker can know that the worker is in a difficult situation and can take care of the worker's anxiety by talking to the superior worker directly.

[0043] On the other hand, if the troubled state of the responsible worker is erroneously detected, or if the responsible worker can check the troubled state or the work procedure manual by tapping the past troubled state displayed on the similar equipment state display screen 410 or the recommended troubled state display screen 420 and can deal with the problem by himself, he can hang up the phone without making a call by tapping the icon on the call display screen 430. In this case, the display on the call display screen 430 can be switched to inform the senior worker that the worker can solve the problem by himself or that he will carry out the past troubled state AAA. Even if the responsible worker is in a troubled state, there are cases where an experienced senior worker or a worker who has been in charge or dealt with the problem in the past judges the state of the industrial equipment at that time to be normal operation, and the responsible worker does not need to work on or deal with the industrial equipment. In this case, if the responsible worker is in a troubled state, it is effective to call the senior worker or a worker who has dealt with the problem in the past, and the industrial equipment is not stopped, so that the operation can be continued without lowering the throughput of the industrial equipment.

[0044] In addition, information on the equipment status of the industrial equipment 110a, information on the troublesome state detected by the worker in charge 130, and the action that the worker in charge 130 plans to take at that time can be transmitted not only to higher-ranking workers but also to the manager of the production support device 200, a higher-ranking manufacturing execution system (MES) 240, or a core information system (ERP: Enterprise Resources Planning). The manager, MES, etc. who receives this information can reflect it in future production plans. In addition, by adjusting the placement and shifts of the worker in charge 130 and higher-ranking workers, a production plan based on events that have actually occurred at the site can be created.

[0045] This can save the call time of the senior worker. Also, when the worker in charge 130 taps on a response method displayed on the input / output means 250a, the input / output means 250b used by the senior worker shown in Fig. 2 displays the tapped response method and the equipment status name of the industrial equipment, so that the senior worker can check whether the judgment of the worker in charge 130 is appropriate or not.

[0046] At this time, if the response method of the worker in charge 130 is not appropriate or if the senior worker wishes to modify the response content, the senior worker can tap the input / output means 250b to input new response content, and the input content can be displayed on the input / output means 250a used by the worker in charge 130. Also, instructions can be transmitted from the senior worker to the worker in charge 130 by phone.

[0047] Furthermore, if the worker in charge 130 is in trouble and the equipment status information of the industrial equipment 110a or the like is urgent, it is possible to inform a senior worker by displaying an emergency on the input / output means 250a or by voice, without waiting for the worker in charge 130 to input a response method or make a call, and to display that the senior worker needs to rush to the worker in charge 130. By having the senior worker rush to the worker in charge 130, an appropriate response can be made immediately.

[0048] As a result, examples of actions and methods of response that should be taken by the less skilled worker 130 in a given situation are provided, enabling the worker 130 to take more appropriate and productive actions and responses, which in turn contributes to improving the production throughput of the entire factory.

[0049] In addition, by informing higher-ranking workers and managers of the anxiety of the worker in charge 130, it is possible to provide the worker in charge 130 with a means to relieve his / her anxiety or an opportunity to consult with him / her, and to make the worker in charge 130 realize that he / she can receive organizational support. This is expected to improve the worker in charge 130's engagement with the organization. Furthermore, improved engagement will increase motivation for everyday work, contributing to improved work efficiency. EXAMPLES

[0050] 5 shows a flowchart of a process for supporting a worker in charge of a support target by the production support device 200. This process starts when the worker in charge of the support target starts work (S500).

[0051] In S510, the image acquisition unit 212 captures images of the support target worker 130 during work from the imaging device 150 at predetermined cycle times.

[0052] In S520, the image processing unit 214 inputs the image data acquired by the image acquisition unit 212 to a classifier or a learning device, and if necessary, also inputs operation information (status mode) of the industrial equipment in charge of the worker in charge, and outputs features representing the work status of the worker in charge.

[0053] The feature values ​​representing the working state of the worker in charge output from one image data are repeatedly obtained. Therefore, based on the feature values ​​or feature values ​​representing the working state of the worker in charge obtained in time series are judged to be outliers or new feature values ​​different from normal work or actions, the image processing unit 214 judges whether or not the worker is in a difficult state with the work or how to deal with it, for example, by the judgment method shown below.

[0054] A method for detecting an anxiety state including an abnormal state, such as when the worker in charge is troubled or confused, as described in the first embodiment, will be described. For example, an unnatural behavior of the worker in charge corresponds to this. An unnatural behavior is when the industrial equipment 110a, etc. is provided with a window through which the inside can be seen, and the worker in charge 130 spends a longer time peeking through the window than usual. The normal time for peeking through the window is stored in the worker information 226 in the storage unit 220 for each worker, and the normal time can be set appropriately with reference to work experience, etc. This is because if the industrial equipment 110a, etc., is behaving abnormally, the time for the worker in charge 130 to peek through the window will increase.

[0055] In addition, a case where the worker in charge 130 peeks into the window of the industrial equipment 110a, etc., more than usual may be determined as an unnatural behavior. This is because if the industrial equipment 110a, etc., is behaving differently from usual, the worker in charge 130 will peek into the window more frequently. Also, if the worker in charge 130 checks the window and there is an unusual sound or vibration, he or she is likely to peek into the window again.

[0056] In addition, the dog may turn its head to look at the industrial equipment 110a or devices adjacent to the industrial equipment 110a, etc., more than usual, or may repeatedly look around at these devices or listen to the sounds of the devices. This is because when the dog becomes worried, it repeatedly checks with its eyes or sounds.

[0057] In addition, when the processing time of the industrial equipment 110a, etc. is longer than expected or when abnormal noise or vibration is occurring, the worker in charge 130 turns toward the industrial equipment 110a, etc., approaches the industrial equipment 110a, etc., and performs the action of approaching the industrial equipment 110a, etc. This is because the worker in charge 130 is likely to be judging or hesitating as to whether or not it is necessary to immediately approach the industrial equipment 110a, etc.

[0058] Another example is when the worker in charge 130 approaches the industrial equipment 110a, etc., has his hand on the emergency stop button, and is performing an action to continue a state in which he can press the emergency stop button at any time. This is because the worker in charge 130 is waiting for the operation of the industrial equipment 110a, etc. to be different from normal and reach a state where an emergency stop should be made, or is in a state where he is unsure of what to do.

[0059] If the image processor 214 determines that the worker in charge 130 is having difficulty dealing with the state of the industrial equipment 110a, etc., the process proceeds to S530. If not, the process proceeds to S510.

[0060] In S530, the industrial equipment status value acquisition unit 213 acquires the status values ​​of the current industrial equipment 110a etc. that the worker in charge 130 is trying to operate but is having difficulty dealing with.

[0061] In S540, the worker support unit 215 searches the database (industrial equipment response history 224) for past status values ​​of the corresponding industrial equipment that correspond to the acquired current status values ​​of the industrial equipment 110a, etc., and calculates the similarity therebetween.

[0062] A method for comparing the current state value of an industrial device with the past state value of the corresponding industrial device will be described. Various sensors are mounted on the industrial device, and the values ​​or states of these sensors (collectively referred to as state values ​​in this embodiment) are acquired. For example, vibration sensors, motor rotation speed, torque, current, voltage, G-code during work, work or control information sent from CAM, etc. These are compared in time series or sensor values ​​on the vertical and horizontal axes to identify feature values. Similarity is identified by comparing feature values ​​obtained from the current state or feature of the industrial device with the past state or feature of the industrial device. At this time, it is preferable to use the sensor values ​​from a state in which the industrial device had a problem or an error in the past as the past state or feature of the industrial device.

[0063] The similarity may be determined by using a predetermined classification method based on the feature quantities of the respective industrial equipment. As an example of the predetermined classification method, supervised or unsupervised learning or reinforcement learning may be used, and more accurate classification can be achieved by using past troubles or error conditions of the industrial equipment as supervised data. Classification may be performed using, but is not limited to, class classification, SVM (Support Vector Machine), decision trees, etc.

[0064] It is preferable to identify and classify the feature quantities of the past states or characteristics of the industrial equipment in advance. In addition, it is preferable to register the current state or characteristics of the industrial equipment when the current worker performs an unnatural movement in a storage means as needed, and also to store the corresponding work content and information on the worker.

[0065] In S550, for data records in which the similarity calculated in S540 is higher than a predetermined value, the worker support unit 215 searches the database (industrial equipment response history 224) for the response methods that workers previously took when the industrial equipment state occurred in the past.

[0066] In S560, the worker support unit 215 identifies a recommended response method (e.g., recommended in order of highest similarity) from among the response methods previously used by workers on the industrial equipment corresponding to the current state of the industrial equipment searched from the database in S550.

[0067] In S570, the worker support unit 215 displays the recommended response method identified in S560 on the similar device status display screen 410 on the input / output means 250a used by the worker in charge 130.

[0068] In S580, the worker support unit 215 receives a selection input from the list of recommended past response methods displayed on the similar device status display screen 410 by the worker in charge and determines whether the similarity of the selected data record is higher than a predetermined value. If the similarity is higher than the predetermined value, the process proceeds to S585a. If the similarity is not higher than the predetermined value, the process proceeds to S585b.

[0069] In S585a, since the past response method selected by the worker in charge in S580 is a past case that is highly similar to the current state of the industrial equipment, the worker support unit 215 supports the current worker in charge by displaying details of the past response method on the input / output means 250a, so that the current worker in charge should use the past response method as a reference for responding to the current state of the industrial equipment.

[0070] In S585b, since the past response method selected by the worker in charge in S580 is a past case that is not highly similar to the current state of the industrial equipment, the worker support unit 215 connects the current worker to the worker who responded in the past or a senior worker for a telephone consultation, and supports the current worker in discussing the response method.

[0071] In S540, if the current state of the industrial equipment does not correspond to the past state of the industrial equipment or does not belong to any state, the similarity with the past state of the industrial equipment cannot be identified, so it is also possible to perform processing to directly call a senior worker (not shown). In this case, since it is unclear how the current worker should respond based on the past state of the industrial equipment, the senior worker can be consulted immediately about the next action, and the time the worker is in trouble can be reduced compared to the conventional method. This allows measures to be taken for industrial equipment where new trouble or errors have occurred, which contributes to improving the operating rate of the industrial equipment.

[0072] The worker in charge 130 in such a situation can be provided with an appropriate method of response, and the worker's anxiety can be alleviated by calling or messaging a senior worker or having a senior worker rush to the scene.

[0073] This embodiment can provide a production support device that contributes to efficiently increasing the work experience of workers, quickly improving their work proficiency, and improving the engagement of workers with little work experience.

[0074] Although one embodiment has been described above, this is merely an example for explaining the present invention, and the scope of the present invention is not limited to this embodiment. The present invention can be implemented in various other forms. [Explanation of symbols]

[0075] 100…Production system 110a, 110b, 110c, 110d...Industrial equipment 120…Work 130...Worker 140...Transportation means (material handling robots, AVG) 150...imaging device 200...Production support equipment 210...Control unit 211…Production Planning Department 212…Image acquisition unit 213...Industrial equipment status value acquisition unit 214...Image processing unit 215…Worker Support Department 216…Image learning section 217…Abnormal sound detection unit 220...Storage section 221…Production Support Program 222…Production planning 223…Industrial equipment status value 224…Industrial equipment support history 225...Image feature extraction parameters 226...Worker information 227...Work procedures and instructions 230…Communications Department 240…Manufacturing Execution System 250a, 250b…I / O means 250c…Screen for worker support 260…Network 410…Similar device status display screen 420…Displays recommended action to take 430…Call display screen

Claims

1. A production support system having industrial equipment, a storage means for storing past operation information of the industrial equipment, an access area for workers who perform work related to the industrial equipment, a detection means for detecting the actions of the workers, and a worker support means for supporting the workers in making decisions regarding their work, the detection means includes an imaging device that acquires image data for confirming a positional relationship between a worker and the industrial equipment and an action of the worker, and an image processing unit that inputs image data from the imaging device and determines whether the worker is in a state where it is difficult to determine the next action to be taken within the area based on a feature amount that represents the working state of the worker, The storage means stores a response method that was taken in the past when an operator was in difficulty in responding to the industrial equipment, in association with operation information that is a status value of the industrial equipment at that time, the worker support means, when it is determined that the worker is in a difficult situation, refers to the storage means to identify past operation information that is identical or similar to current operation information when the industrial equipment is operating, and identifies a recommended response method for the worker based on the identified past operation information; and an input / output means as a display means for displaying the recommended response method.

2. 2. The production support system according to claim 1, wherein the worker support means reads from a database stored in the storage means record information of response methods used in the past for past cases in which past operation information of the industrial equipment is highly similar to current operation information, displays a list of response methods used in the past in order of most similar past cases on the input / output means used by the worker, and accepts a selection by the worker.

3. The production support system according to claim 2, characterized in that, when the past response method selected by the worker is a past case whose similarity to the current operation information of the industrial equipment is not higher than a predetermined value, the worker support means connects the worker to a worker who responded in the past or a senior worker for a telephone consultation, and supports the worker to consult on the response method.

4. 3. The production support system according to claim 2, wherein the database is composed of data records each including an equipment status name for identifying cases where measures have been taken in the past for each piece of industrial equipment, a status value of the industrial equipment, a past response method, and a name of a worker who responded in the past.

5. The production support system according to claim 2, characterized in that the worker support means, as an interface for supporting the worker who is in a difficult situation as to what action to take with respect to the industrial equipment, displays on the input / output means a similar equipment status display screen which displays a list of past response methods in order of most similar past cases, a recommended response method display screen, and a call display screen which connects a call to a worker who has previously responded to the equipment status in question.

6. 2. The production support system according to claim 1, wherein the detection means receives image data of the worker to be supported while working at predetermined cycle times and operation information of the industrial equipment, and outputs a feature quantity representing the working state of the worker.

7. A production support method for a system having industrial equipment, a storage means for storing past operation information of the industrial equipment, an access area for a worker performing work related to the industrial equipment, a detection means for detecting the movement of the worker, a worker support means for supporting the worker in making decisions regarding the work, and a database for storing past operation information of the industrial equipment, the method comprising the steps of: The system includes an image acquisition means, a storage means for storing a response method taken in a past situation where an operator was unable to respond to the industrial equipment in association with operation information of the industrial equipment at that time, which is a status value of the industrial equipment, and an operator support means, a step of acquiring image data of a worker to be supported during work at a predetermined cycle time by the image acquisition means; the detection means extracting features representing the working state of the worker from the acquired image data and operation information of the industrial equipment, and recognizing that the state of the industrial equipment in charge of the worker is different from a normal state based on the features representing the working state of the worker obtained in time series, and identifying a state in which the worker is having difficulty dealing with the situation; The worker support means acquires operation information of the industrial equipment according to the identification of the situation that the worker is having difficulty dealing with; the worker support means searches the database for past operation information of the industrial equipment corresponding to the acquired current operation information of the industrial equipment, calculates a similarity between the two pieces of operation information, reads out information on past response methods for the past operation information of the industrial equipment that is highly similar, and presents candidates for recommended response methods to the worker; A production support method comprising the steps of:

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