ANOMALYSIS DETECTION DEVICE, ANOMALYSIS DETECTION METHOD, AND ANOMALYSIS DETECTION PROGRAM

Abstract

To provide an anomaly detection device capable of detecting an anomaly in a manufacturing plant.SOLUTION: An anomaly detection device 100 acquires a planned production, which indicates the pre-planned production volume of a product and which a production volume of a product produced during a predetermined period using equipment installed in a factory and an actual production volume representing the production volume of the product that has been produced during the predetermined period. The anomaly detection device 100 compensates the planned production by the product yield rate and detects an anomaly in the plant based on the compensated planned production and the actual production volume.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to an abnormality detection device and the like. [Background technology]

[0002] In manufacturing plants, products are produced based on production plans, but various abnormalities occur daily, and there are cases where products cannot be produced according to the production plan. In order to mitigate the impact of such abnormalities, various information is shared between multiple manufacturing plants, and measures such as adjusting production volume are taken. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2004-178465 A [Patent Document 2] JP 2005-050176 A [Patent Document 3] JP 2005-092689 A [Patent Document 4] JP 2002-373012 A Summary of the Invention [Problem to be solved by the invention]

[0004] As described above, when products cannot be produced according to the production plan, it is assumed that some kind of abnormality has occurred. However, it can be difficult to identify the cause of the inability to produce according to the production plan, and the manager's response may be delayed.

[0005] For example, in addition to equipment failure at the manufacturing plant, reasons for not being able to produce according to the production plan could include employees skimming products or the manufacturing plant being operated improperly.

[0006] In one aspect, the present invention aims to provide an abnormality detection device, an abnormality detection method, and an abnormality detection program capable of detecting an abnormality in a manufacturing plant. [Means for solving the problem]

[0007] In a first proposal, the anomaly detection device includes an acquisition unit and a detection unit. The acquisition unit acquires a planned production volume, which is a production volume of a product produced in a predetermined period using equipment installed in a factory, and indicates a production volume of a product planned in advance, and an actual production volume, which indicates a production volume of a product actually produced in the predetermined period. The detection unit corrects the planned production volume by the product yield rate, and detects an anomaly in the factory based on the corrected planned production volume and the actual production volume. Effect of the Invention

[0008] Abnormalities in manufacturing plants can be detected. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram illustrating an anomaly detection system according to the present embodiment. [Diagram 2] FIG. 2 is a diagram illustrating an example of a data structure of the management DB. [Diagram 3] FIG. 3 is a functional block diagram showing the configuration of the abnormality detection device according to the present embodiment. [Figure 4] FIG. 4 is a diagram illustrating an example of a data structure of the work table. [Diagram 5] FIG. 5 is a flowchart (1) showing a processing procedure of the abnormality detection device according to the present embodiment. [Figure 6] FIG. 6 is a flowchart (2) showing the processing procedure of the abnormality detection device according to the present embodiment. [Figure 7] FIG. 7 is a diagram illustrating an example of a hardware configuration of a computer that realizes the same functions as the abnormality detection device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of the anomaly detection device, an anomaly detection method, and an anomaly detection program disclosed in the present application will be described in detail with reference to the accompanying drawings. Note that the present invention is not limited to the embodiment. EXAMPLES

[0011] Fig. 1 is a diagram showing an anomaly detection system according to the present embodiment. As shown in Fig. 1, this system includes a manufacturing factory 3, an administrator terminal 10, a server 20, and an anomaly detection device 100. The server 20 is connected to the manufacturing factory 3 (a terminal device (not shown) installed in the manufacturing factory 3). The administrator terminal 10, the server 20, and the anomaly detection device 100 are connected to each other via a network 5. Note that the anomaly detection device 100 may also be directly connected to the server 20 without going through the network 5.

[0012] The manufacturing factory 3 is a factory where equipment is installed and employees operate the equipment to produce products. Terminal devices are installed in the manufacturing factory 3, and the terminal devices record the actual production volume for each specified period. In the following explanation, the production volume of products actually produced in a specified period is referred to as the "actual production volume." The terminal devices in the manufacturing factory 3 record the actual production volume for each day, and transmit information on the actual production volume with dates attached to it to the server 20.

[0013] Furthermore, the terminal device of the manufacturing factory 3 records the actual operation time of the equipment for each predetermined period. In the following description, the actual operation time for each predetermined period is referred to as the “actual operation time.” The terminal device of the manufacturing factory 3 records the actual operation time for each day, and transmits information on the actual operation time with a date attached thereto to the server 20.

[0014] The manager terminal 10 is a terminal device used by the manager of the manufacturing factory 3. The manager operates the manager terminal 10 to input the planned production volume. The planned production volume is the production volume of products produced in a specified period, and indicates the production volume of products planned in advance. For example, the manager inputs the planned production volume for each day. The manager terminal 10 transmits the planned production volume with the date attached to the server 20. Furthermore, if there is a change in the planned production volume, the server 20 is notified of information including the date and the fact that there has been a change in the planned production volume.

[0015] The administrator also operates the administrator terminal 10 to input the scheduled operation time. The scheduled operation time is the amount of time that the device will operate per day that has been scheduled in advance. The administrator terminal 10 transmits the scheduled operation time with the date attached to it to the server 20.

[0016] The server 20 registers the information received from the terminal device in the manufacturing factory 3 and the manager terminal 10 in the management DB 141. The server 20 transmits the information in the management DB 141 to the abnormality detection device 100.

[0017] 2 is a diagram showing an example of the data structure of the management DB 141. As shown in FIG. 2, the management DB 141 has item numbers, dates, planned production amounts, scheduled operation times, actual production amounts, actual operation times, and plan change flags.

[0018] The item number is a number that identifies the record in the management DB. The date is the date that corresponds to the record. The planned production volume and the scheduled operation time are information transmitted from the manager terminal 10 and are associated with the date. The actual production volume and the actual operation time are information transmitted from the terminal device of the manufacturing factory 3 and are associated with the date.

[0019] The plan change flag indicates whether or not there has been a change in the planned production volume on the corresponding date. For example, if there has been a change in the planned production volume, the flag is set to "on," and if there has been no change in the planned production volume, the flag is set to "off."

[0020] The abnormality detection device 100 receives the management DB 141 from the server 20, and detects an abnormality in the manufacturing factory 3 based on the management DB 141. When an abnormality is detected, the abnormality detection device 100 notifies the administrator that an abnormality has been detected in the manufacturing factory 3 by displaying a warning screen on the administrator terminal 10.

[0021] For example, the abnormality detection device 100 corrects the planned production volume by the product yield rate, and detects an abnormality in the manufacturing factory 3 based on the corrected planned production volume and the actual production volume. Furthermore, the abnormality detection device 100 detects an abnormality in the manufacturing factory 3 when the actual operation time is longer than the scheduled operation time and there is no change in the production plan at the relevant date and time.

[0022] By executing the above process, the abnormality detection device 100 can detect an abnormality in the manufacturing factory 3. Furthermore, the abnormality detection device 100 notifies an administrator of the occurrence of an abnormality, so that the administrator can efficiently take measures to deal with the abnormality.

[0023] Next, an example of the configuration of the abnormality detection device 100 shown in Fig. 1 will be described. Fig. 3 is a functional block diagram showing the configuration of the abnormality detection device according to this embodiment. As shown in Fig. 3, the abnormality detection device 100 has a communication unit 110, an input unit 120, a display unit 130, a storage unit 140, and a control unit 150.

[0024] The communication unit 110 is a processing unit that executes data communication between the administrator terminal 10 and the server 20 via the network 5. The communication unit 110 is an example of a communication device. The communication unit 110 may receive data from other external devices (not shown).

[0025] The input unit 120 is an input device that inputs various pieces of information to the control unit 150 of the abnormality detection device 100. The input unit 120 corresponds to a keyboard, a mouse, a touch panel, or the like.

[0026] The display unit 130 is a display device that displays information output from the control unit 150. For example, the display unit 130 displays screen information such as skill certification and scoring results of various competitions. The display unit 130 corresponds to a liquid crystal display, an organic EL (Electro-Luminescence) display, a touch panel, etc.

[0027] The storage unit 140 includes a management DB 141, a work table 142, and yield information 143. The storage unit 140 corresponds to a semiconductor memory element such as a RAM (Random Access Memory) or a flash memory, or a storage device such as an HDD (Hard Disk Drive).

[0028] The management DB 141 is information received from the server 20. The data structure of the management DB 141 is similar to the data structure of the management DB 141 described in FIG.

[0029] The work table 142 is a table that holds the work information of each employee. FIG. 4 is a diagram showing an example of the data structure of the work table. As shown in FIG. 4, this work table 142 associates an employee ID with work information. The employee ID is information that uniquely identifies an employee working in the manufacturing factory 3. The work information is set with the arrival time and departure time for each date. For example, a date for an employee for which the arrival time and departure time are not set indicates that the employee is absent. There may be cases where the arrival time is recorded but the departure time is not recorded due to some reason.

[0030] The yield information 143 is information on the yield rate of products produced by the equipment in the manufacturing factory 3. The yield rate in this embodiment is the rate at which products produced by the equipment in the manufacturing factory 3 are properly produced, and the closer the yield rate is to 1, the closer the actual production volume is to the planned production volume.

[0031] The control unit 150 includes an acquisition unit 151, a detection unit 152, and a warning unit 153. The control unit 150 is realized by a hardwired logic such as a central processing unit (CPU), a graphics processing unit (GPU), an application specific integrated circuit (ASIC), or a field programmable gate array (FPGA).

[0032] The acquisition unit 151 acquires information of the management DB 141 from the server 20. The acquisition unit 151 stores the acquired information of the management DB 141 in the storage unit 140. In addition, the acquisition unit 151 acquires work information corresponding to each employee ID from the server 20 or another external device, and updates the work table 142.

[0033] The detection unit 152 detects an abnormality in the manufacturing plant 3 based on the management DB 141. An example of the process of the detection unit 152 will be described below.

[0034] The next process is executed by acquiring records of the planned production volume, scheduled operation time, actual production volume, actual operation time, and plan change flag corresponding to the same date from the detection unit 152. The detection unit 152 may select the most recent date with priority, or may select records in ascending order of date and execute the next process.

[0035] The detection unit 152 corrects the planned production volume based on the yield information 143. For example, the detection unit 152 corrects the planned production volume by multiplying the planned production volume by the yield rate set in the yield information 143. In the following description, the corrected planned production volume will be referred to as a "corrected production volume."

[0036] The detection unit 152 detects the presence or absence of an abnormality in the manufacturing factory 3 and the details of the abnormality based on a combination of the following conditions. When the detection unit 152 detects an abnormality, it outputs the detection result to the warning unit 153. The detection result includes the date and the details of the abnormality. The thresholds th1, th2, and th3 are set in advance by the administrator.

[0037] Corrected production volume <= Actual production volume (Condition 1) Actual operating time / Planned operating time > Threshold th1... (Condition 2) Actual operating time < planned operating time (Condition 3) Actual production volume / corrected production volume < threshold th2 (condition 4) Actual operating time - Planned operating time > Threshold th3... (Condition 5) Plan change flag is "OFF" (Condition 6)

[0038] When Condition 1 and Condition 2 are satisfied, the detection unit 152 detects an abnormality in the manufacturing factory 3. In this case, the detection unit 152 detects the content of the abnormality in the manufacturing factory 3 as “unauthorized operation of the manufacturing factory”.

[0039] When Condition 1 and Condition 3 are satisfied, the detection unit 152 detects an abnormality in the manufacturing factory 3. In this case, the detection unit 152 detects that the content of the abnormality in the manufacturing factory 3 is "equipment failure".

[0040] When Condition 1 and Condition 4 are satisfied but Condition 3 is not satisfied, the detection unit 152 detects an abnormality in the manufacturing factory 3. In this case, the detection unit 152 detects the content of the abnormality in the manufacturing factory 3 as “hollowing out of products”.

[0041] If condition 5 and condition 6 are satisfied, the detection unit 152 detects an abnormality in the manufacturing factory 3. In this case, the detection unit 152 detects the content of the abnormality in the manufacturing factory 3 as "unauthorized operation of the factory." In addition, the detection unit 152 scans the work information in the work table 142 using the date of the selected record as a key, and determines whether there is an employee ID for which the arrival time at work is recorded and the departure time is not recorded on the key date.

[0042] If there is an employee ID for which the time of arrival at work is recorded but the time of leaving work is not recorded on the key date, the detection unit 152 detects the employee ID. The detection unit 152 outputs the detected employee ID to the warning unit 153 as the "employee ID of an employee who has not left work."

[0043] The detection unit 152 repeatedly executes the above process for records (planned production volume, scheduled operation time, actual production volume, actual operation time, plan change flag) for each date included in the management DB 141, and outputs the detection result to the warning unit 153.

[0044] The warning unit 153 issues a warning to the manager terminal 10 based on the detection result from the detection unit 152. For example, the warning unit 153 transmits information on a warning screen indicating the contents of the abnormality to the manager terminal 10 to display it. If the detection result includes the employee ID of an employee who has not left the company, the warning unit 153 sets the employee ID of the employee who has not left the company on the warning screen.

[0045] Next, an example of a processing procedure of the abnormality detection device 100 according to this embodiment will be described. Fig. 5 is a flowchart (1) showing a processing procedure of the abnormality detection device according to this embodiment. The acquisition unit 151 of the abnormality detection device 100 acquires information of the management DB 141 from the server 20, and stores it in the storage unit 140 (step S101).

[0046] The detection unit 152 of the abnormality detection device 100 acquires the planned production volume, the actual production volume, the planned operation time, and the actual operation time for a certain date from the management DB 141 (step S102).

[0047] The detection unit 152 corrects the planned production volume based on the yield rate (step S103). If the detection unit 152 satisfies condition 1 (corrected production volume≦actual production volume) (step S104, Yes), the process proceeds to step S105. On the other hand, if the detection unit 152 does not satisfy condition 1 (step S104, No), the process proceeds to step S107.

[0048] Step S105 and subsequent steps will be described. The detection unit 152 determines whether or not condition 2 (actual operation time / scheduled operation time>threshold th1) is met (step S105). If condition 2 is met (step S105, Yes), the detection unit 152 detects unauthorized operation of the factory, and the warning unit 153 issues a warning to the manager terminal 10 (step S106). On the other hand, if condition 2 is not met (step S105, No), the detection unit 152 ends the process.

[0049] Step S107 and subsequent steps will be described. The detection unit 152 determines whether or not condition 3 (operation rate actual time<scheduled operation time) is satisfied (step S107). If condition 3 is satisfied (step S107, Yes), the detection unit 152 detects a device failure, and the warning unit 153 issues a warning to the manager terminal 10 (step S108). On the other hand, if condition 3 is not satisfied (step S107, No), the detection unit 152 proceeds to step S109.

[0050] Step S109 and subsequent steps will be described. The detection unit 152 determines whether or not condition 4 (actual production volume / corrected production volume<threshold th2) is satisfied (step S109). If condition 4 is satisfied (step S109, Yes), the detection unit 152 detects hollowing out of the product, and the warning unit 153 issues a warning to the manager terminal 10 (step S110). On the other hand, if condition 4 is not satisfied (step S109, No), the detection unit 152 ends the process.

[0051] 6 is a flowchart (2) showing the processing procedure of the anomaly detection device according to the present embodiment. The detection unit 152 of the anomaly detection device 100 acquires the planned operation time, the actual operation time, and the plan change flag from the management DB 141 (step S201). The detection unit 152 determines whether or not the condition 5 (actual operation time-planned operation time>threshold value th3) ​​is satisfied (step S202). If the condition 5 is not satisfied (step S202, No), the detection unit 152 ends the processing. On the other hand, if the condition 5 is satisfied (step S202, Yes), the detection unit 152 proceeds to step S203.

[0052] The detection unit 152 determines whether or not Condition 6 is satisfied (Step S203). If Condition 6 is not satisfied (Step S203, No), the detection unit 152 ends the process. On the other hand, if Condition 6 is satisfied (Step S203, Yes), the detection unit 152 refers to the work table 142 and determines whether or not there is a person who has not left on the corresponding date (Step S204).

[0053] If there is a person who has not left (step S205, Yes), the detection unit 152 detects unauthorized operation of the manufacturing plant and the employee ID of the person who has not left, and the warning unit 153 issues a warning (step S206). On the other hand, if there is no person who has not left (step S205, No), the detection unit 152 detects unauthorized operation of the manufacturing plant, and the warning unit 153 issues a warning (step S207).

[0054] Next, the effects of the anomaly detection device according to this embodiment will be described. The anomaly detection device 100 acquires the planned production volume and the actual production volume from the management DB 141, and corrects the planned production volume based on the yield. The anomaly detection device 100 detects an anomaly in the manufacturing factory 3 based on the corrected planned production volume and the actual production volume. This makes it possible to detect an anomaly in the manufacturing factory 3 when products are not being produced according to the production plan.

[0055] The abnormality detection device 100 acquires the planned operation time and the actual operation time from the management DB 141, and if the actual operation time is longer than the planned operation time, determines whether there is a change in the production plan for the product, and detects an abnormality if there is no change in the production plan. This makes it possible to detect unauthorized operation from the contents of multiple abnormalities that may occur in the manufacturing factory 3.

[0056] The anomaly detection device 100 detects unauthorized operation of the equipment in the manufacturing factory 3 when the corrected planned production volume is equal to or less than the actual production volume and the value obtained by dividing the actual operation time by the scheduled operation time is greater than a predetermined value. This makes it possible to detect unauthorized operation from the contents of multiple anomalies that may occur in the manufacturing factory 3.

[0057] The abnormality detection device 100 detects an equipment failure when the corrected planned production volume becomes larger than the actual production volume and the actual operation time is smaller than the scheduled operation time. This makes it possible to detect an equipment failure from the contents of multiple abnormalities that may occur in the manufacturing plant 3.

[0058] The abnormality detection device 100 detects hollowing out of products when the corrected planned production volume becomes larger than the actual production volume, the actual operation time is equal to or longer than the scheduled operation time, and the value obtained by dividing the actual production volume by the planned production volume is smaller than a predetermined value. This makes it possible to detect hollowing out of products from the contents of multiple abnormalities that may occur in the manufacturing plant 3.

[0059] Furthermore, when an abnormality is detected, the abnormality detection device 100 notifies the administrator terminal 10 of the detection result, so that the administrator can efficiently take measures to deal with the abnormality.

[0060] Next, a description will be given of an example of a hardware configuration of a computer that realizes the same functions as the abnormality detection device 100 shown in the above embodiment. Fig. 7 is a diagram showing an example of a hardware configuration of a computer that realizes the same functions as the abnormality detection device.

[0061] 7, the computer 200 has a CPU 201 that executes various arithmetic processes, an input device 202 that accepts data input from a user, and a display 203. The computer 200 also has a communication device 204 that receives data from the server 20, and an interface device 205 that connects to various devices. The computer 200 has a RAM 206 that temporarily stores various information, and a hard disk device 207. The devices 201 to 207 are connected to a bus 208.

[0062] The hard disk drive 207 includes an acquisition program 207a, a detection program 207b, and a warning program 207c. The CPU 201 reads out the acquisition program 207a, the detection program 207b, and the warning program 207c, and loads them in the RAM 206.

[0063] The acquisition program 207a functions as an acquisition process 206a. The detection program 207b functions as a detection process 206b. The warning program 207c functions as a warning process 206c.

[0064] The processing of the acquisition process 206a corresponds to the processing of the acquisition unit 151. The processing of the detection process 206b corresponds to the processing of the detection unit 152. The processing of the warning process 206c corresponds to the processing of the warning unit 153.

[0065] It is not necessary that each of the programs 207a to 207c is stored in the hard disk device 207 from the beginning. For example, each of the programs may be stored in a "portable physical medium" such as a flexible disk (FD), a CD-ROM, a DVD disk, a magneto-optical disk, or an IC card that is inserted into the computer 200. Then, the computer 200 may read and execute each of the programs 207a to 207c. [Explanation of symbols]

[0066] 100 Anomaly detection device 110 Communications Department 120 Input section 130 Display section 140 Storage section 141 Management DB 142 Work Table 143 Yield Information 150 Control section 151 Acquisition Department 152 Detection unit 153 Warning section

Claims

1. an acquisition unit that acquires a planned production volume indicating a production volume of a product to be produced in a predetermined period using equipment installed in a factory, the planned production volume indicating a production volume of a product planned in advance, an actual production volume indicating a production volume of a product actually produced in the predetermined period, a planned operation time indicating a time when the equipment is scheduled to operate, and an actual operation time indicating a time when the equipment actually operated; a detection unit that, when a time obtained by subtracting the planned operation time from the actual operation time is greater than a predetermined time, identifies whether or not there is a change in a production plan for a product, and, when there is no change in the production plan, corrects the planned production volume by a yield rate of the product, and detects an abnormality in the factory based on the corrected planned production volume and the actual production volume; An abnormality detection device comprising:

2. 2. The anomaly detection device according to claim 1, wherein the detection unit detects unauthorized operation of the equipment when the corrected planned production volume is equal to or less than the actual production volume and a value obtained by dividing the actual operation time by the scheduled operation time is greater than a predetermined value.

3. 3. The abnormality detection device according to claim 2, wherein the detection unit detects a failure of the equipment when the corrected planned production volume becomes greater than the actual production volume and the actual operation time is shorter than the scheduled operation time.

4. 4. The anomaly detection device according to claim 3, wherein the detection unit detects hollowing out of a product when the corrected planned production volume becomes larger than the actual production volume, the actual operation time is equal to or longer than the scheduled operation time, and a value obtained by dividing the actual production volume by the planned production volume is smaller than a predetermined value.

5. 1. A computer-implemented method for detecting anomalies, comprising: A production volume of a product produced in a predetermined period using equipment installed in a factory is acquired, the planned production volume indicating a production volume of a product planned in advance, an actual production volume indicating a production volume of a product actually produced in the predetermined period, a planned operation time indicating a time when the equipment is scheduled to operate, and an actual operation time indicating a time when the equipment actually operated, If the time obtained by subtracting the planned operation time from the actual operation time is greater than a predetermined time, it is determined whether there is a change in the production plan for the product, and if there is no change in the production plan, the planned production volume is corrected by the yield rate of the product, and an abnormality in the factory is detected based on the corrected planned production volume and the actual production volume.

2. An anomaly detection method comprising:

6. On the computer, A production volume of a product produced in a predetermined period using equipment installed in a factory is acquired, the planned production volume indicating a production volume of a product planned in advance, an actual production volume indicating a production volume of a product actually produced in the predetermined period, a planned operation time indicating a time when the equipment is scheduled to operate, and an actual operation time indicating a time when the equipment actually operated, If the time obtained by subtracting the planned operation time from the actual operation time is greater than a predetermined time, it is determined whether there is a change in the production plan for the product, and if there is no change in the production plan, the planned production volume is corrected by the yield rate of the product, and an abnormality in the factory is detected based on the corrected planned production volume and the actual production volume.

4. An anomaly detection program for executing a process.

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