Maintenance plan formulation system, maintenance plan formulation method, and program

Abstract

To provide a maintenance planning system, a maintenance planning method and a program for suppressing, to a possible minimum, the stoppage of lines in the post-process due to implementation of maintenance work.SOLUTION: A maintenance planning system 100 according to the present disclosure comprises a failure prediction unit 23, a stock amount prediction unit 44 and a maintenance time setting unit 33. The failure prediction unit 23 predicts a grace period until equipment goes down on the basis of equipment information of equipment used in a target process among a plurality of processes included in a production line. The stock amount prediction unit 44 predicts temporal transition of stock amounts of components having been processed in the target process and supplied to post-processes of the target process, on the basis of production plan information in the production line. The maintenance time setting 33 sets a maintenance time at which maintenance work on equipment should be performed within the grace period on the basis of the temporal transition of stock amounts of components.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a maintenance plan creation system, a maintenance plan creation method, and a program.

Background Art

[0002] In Patent Document 1, by monitoring preventive maintenance data of equipment (machinery) at a predetermined cycle, deterioration of parts is detected, and based on the remaining period until the parts reach the end of their life, a technique for creating a plan for maintenance work (equipment repair, maintenance, etc.) including part replacement work is disclosed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In Patent Document 1, maintenance work is usually carried out during non - operating hours when the line is stopped. For example, in a line that operates continuously, there is a problem that maintenance work cannot be carried out during non - operating hours, and it is necessary to stop the line in the subsequent process for maintenance work in some processes.

[0005] In view of such problems, an object of the present invention is to provide a maintenance plan creation system, a maintenance plan creation method, and a program that minimize the stop of the line in the subsequent process due to performing maintenance work.

Means for Solving the Problems

[0006] The maintenance plan creation system of the present disclosure is a failure prediction unit that predicts a remaining period until the equipment fails based on equipment information of equipment used in a target process among a plurality of processes included in a production line, an inventory quantity prediction unit that predicts, based on production plan information for the production line, a time transition of an inventory quantity of parts that are processed in the target process and supplied to a process subsequent to the target process; and a maintenance timing setting unit that sets a maintenance timing for performing maintenance work on the equipment within the grace period based on the time transition of the inventory amount of the parts.

[0007] The maintenance planning method of the present disclosure includes: predicting a grace period until a piece of equipment used in a target process among a plurality of processes included in a production line based on equipment information of the equipment; predicting, based on production plan information for the production line, a time transition of inventory amounts of parts processed in the target process and supplied to a process subsequent to the target process; The computer sets a maintenance timing for performing maintenance work on the equipment within the grace period based on the change in the inventory amount over time.

[0008] The program of the present disclosure is A process of predicting a grace period until a piece of equipment used in a target process among a plurality of processes included in a production line based on equipment information of the equipment; a process for predicting, based on production plan information for the production line, a time transition of an inventory amount of parts to be processed in the target process and supplied to a process subsequent to the target process; and setting a maintenance timing for performing maintenance work on the equipment within the grace period based on the change in the inventory amount over time. [Effects of the Invention]

[0009] In view of such problems, the present invention can provide a maintenance planning system, a maintenance planning method, and a program that minimize stoppages of downstream process lines due to maintenance work. [Brief explanation of the drawings]

[0010]

Figure 1

Figure 2

Figure 3

Mode for Carrying Out the Invention

[0011] Hereinafter, specific embodiments to which the present invention is applied will be described in detail with reference to the drawings. In each drawing, the same reference numerals are assigned to the same elements, and redundant descriptions will be omitted as necessary for clarity of explanation.

[0012] (First Embodiment) First, with reference to FIG. 1, the configuration of a maintenance plan creation system 100 according to the first embodiment will be described. The maintenance plan creation system 100 is a system for creating a maintenance plan for each piece of equipment 1 used in a plurality of processes (for example, processes A to C) included in a production line L that produces products. The maintenance plan is a plan for operations such as adjusting equipment and replacing parts in order to maintain the equipment in a state where it can operate perfectly.

[0013] In this embodiment, the equipment used in processes A to C of the production line L is collectively referred to as equipment 1. In process A, equipment 1A (equipment 1A1 to equipment 1An) is used. In process B, equipment 1B (equipment 1B1 to equipment 1Bn) is used. In process C, equipment 1C (equipment 1C1 to equipment 1Cn) is used.

[0014] The maintenance plan creation system 100 includes a logistics and production status monitoring unit 10, a sign detection unit 20, a maintenance plan unit 30, and a production plan unit 40. Note that the maintenance plan creation system 100 may be realized by a plurality of devices that communicate with each other, or may be realized by a single device.

[0015] The Logistics and Production Status Monitoring Unit 10 monitors the logistics status and production status in each process (Process A to Process C). The Logistics and Production Status Monitoring Unit 10 includes a Logistics and Production Status DB (Data base) 11. The Logistics and Production Status DB 11 stores information regarding the transportation status of parts transported from suppliers or other factories using the parts transport vehicle 2 in each process. The logistics status of the parts includes, for example, the position information of the parts transport vehicle 2. In addition, the Logistics and Production Status DB 11 stores the production status of the parts in each process.

[0016] The Sign Detection Unit 20 detects signs of failure of the equipment 1. The Sign Detection Unit 20 includes a Failure History DB 21, an Equipment Monitoring Unit 22, a Failure Prediction Unit 23, and a Failure Prediction DB 24. The Failure History DB 21 stores the failure history of each equipment 1. The failure history is, for example, the failure time of the equipment 1 and the details of the failure of the equipment 1.

[0017] The Equipment Monitoring Unit 22 monitors the equipment 1. The Equipment Monitoring Unit 22 acquires equipment information of the equipment 1 from the equipment 1. The equipment information includes, for example, information such as current value, vibration, and sound. The Failure Prediction Unit 23 predicts the period (hereinafter referred to as the remaining period) until the equipment 1 reaches the end of its life from the equipment information of the equipment 1. By doing so, the Failure Prediction Unit 23 predicts the time and scale at which a failure of the equipment 1 will occur.

[0018] The Failure Prediction DB 24 stores information predicting the time and scale at which a failure of each equipment 1 will occur. For example, the Failure Prediction DB 24 stores the remaining period information of the equipment 1.

[0019] The Maintenance Planning Unit 30 formulates a maintenance plan for each equipment 1. The Maintenance Planning Unit 30 includes a Maintenance History DB 31, a Working Period Calculation Unit 32, a Maintenance Time Setting Unit 33, and a Maintenance Plan DB 34.

[0020] The Maintenance History DB 31 stores the maintenance history information of each equipment 1. The maintenance history information is the history information of the maintenance work performed on the equipment 1B1 in the past.

[0021] The operation period calculation unit 32 calculates the period required for the maintenance work of the facility 1 (hereinafter referred to as the maintenance work period) based on the facility information of the facility 1. Further, the operation period calculation unit 32 calculates the maintenance work period of the facility 1 based on the maintenance history information.

[0022] The maintenance time setting unit 33 sets the time (hereinafter referred to as the maintenance time) for performing the maintenance work of the facility 1 within the buffer period based on the temporal change in the inventory quantity of the parts processed in the process using the facility 1 (target process) and supplied to the subsequent process of the target process. The maintenance time indicates the maintenance start time for starting the maintenance work and the maintenance end time for ending the maintenance work. By doing so, the maintenance time setting unit 33 formulates a maintenance plan by setting the maintenance time.

[0023] Specifically, the maintenance time setting unit 33 sets the maintenance time of the facility 1 within the buffer period so that the inventory quantity of the parts in the target process does not fall below a predetermined threshold within the maintenance work period. Since the production of the facility 1 stops during the maintenance work period of the facility 1, the inventory quantity of the parts in the target process decreases. If the inventory quantity of the parts is insufficient, there is a possibility that the line will stop in the subsequent process of the target process. In order to suppress the line stop, the maintenance time setting unit 33 sets the maintenance time of the facility 1 within the buffer period so that the inventory quantity of the parts does not become insufficient within the maintenance work period.

[0024] On the other hand, if the maintenance time setting unit 33 cannot set the maintenance time of the facility 1 within the buffer period so that the inventory quantity of the parts in the target process does not fall below a predetermined threshold within the maintenance work period, the maintenance time is temporarily set. Then, the maintenance time setting unit 33 sends an instruction to correct the production plan to the production plan creation unit 42. The maintenance plan DB 34 stores the maintenance plan information of each facility 1.

[0025] The production planning department 40 formulates the production plan for the production line L. The production plan indicates plans regarding the production volume and production time of the equipment 1 in each process included in the production line L. The production planning department 40 is provided with an upper-level plan and demand forecasting DB 41, a production plan creation department (production plan modification department) 42, a production plan DB 43, an inventory quantity forecasting unit 44, and an inventory quantity trend forecasting DB 45.

[0026] The upper-level plan and demand forecasting DB 41 stores upper-level plan information and demand forecasting information. The upper-level plan is a sales plan or production plan such as annual, monthly, or weekly.

[0027] The production plan creation department 42 creates a production plan using the upper-level plan information, demand forecasting information, and maintenance plan information. The production plan creation department 42 refers to the maintenance plan information for each process (including the maintenance plan information with the maintenance time temporarily set) so as to meet the required number of production for the year, month, and week, and creates a production plan for each time segment of the day (such as every hour or every 15 minutes).

[0028] Also, when the production plan creation department 42 obtains an instruction to modify the production plan from the maintenance time setting unit 33, it modifies the production plan. For example, the production plan creation department 42 increases the production volume of the equipment 1 for the parts in the target process during a predetermined period so that the inventory quantity of the parts in the target process does not fall below a predetermined threshold within the maintenance work period. Also, the production plan creation department 42 decreases the production volume of the equipment 1 in the subsequent process during a predetermined period so that the inventory quantity in the target process does not fall below a predetermined threshold within the maintenance work period. The production plan DB 43 stores the production plan information for the production line L.

[0029] The inventory quantity forecasting unit 44 predicts the temporal change of the inventory quantity in each process based on the production plan information. Also, when the inventory quantity forecasting unit 44 detects that an abnormality has occurred in the subsequent process from the logistics status and production status information of the logistics and production status DB 11, it updates the prediction of the temporal change of the inventory quantity in the target process based on the abnormal situation in the subsequent process. The inventory quantity trend forecasting DB 45 stores the created inventory quantity trend forecasting information.

[0030] Next, with reference to FIG. 2, an example of the operation of the maintenance plan creation system 100 according to the first embodiment will be described. Hereinafter, as an example, the operation of creating a maintenance plan for the facility 1B1 used in process B by the maintenance plan creation system 100 will be described.

[0031] First, the facility monitoring unit 22 of the symptom detection unit 20 acquires the facility information of the facility 1B1 used in process B. The facility information is, for example, the current value, vibration, sound, etc. of the facility 1B1. Next, the failure prediction unit 23 predicts the remaining period until a failure occurs in the facility 1B1 from the facility information of the facility 1B1 (step S101). Further, the failure prediction unit 23 may predict the remaining period of the facility 1B1 from the failure history information acquired from the failure history DB 21. The failure prediction DB 24 stores the predicted remaining period information of the facility 1B1.

[0032] Note that the failure prediction unit 23 may predict the remaining period of the facility 1B1 using machine learning from past performance data. The past performance data is, for example, data that associates past facility information and remaining period information.

[0033] Next, the inventory quantity prediction unit 44 of the production planning unit 40 acquires the production plan information in the production line from the production plan DB 43. Next, the inventory quantity prediction unit 44 predicts the temporal change of the inventory quantity of the parts processed in process B and supplied to process C, which is the subsequent process (hereinafter, the inventory quantity of the parts in process B) from the production plan information (step S102). That is, the inventory quantity prediction unit 44 predicts how the inventory quantity of the parts in process B changes from the present to a predetermined period after the present. Here, the inventory quantity change prediction DB 45 stores the temporal change prediction information of the inventory quantity of the parts in process B.

[0034] Next, the work period calculation unit 32 of the maintenance plan unit 30 acquires the maintenance history information of the facility 1B1 from the maintenance history DB 31. The maintenance history information is the history information of the maintenance work performed on the facility 1B1 in the past. Next, the work period calculation unit 32 calculates the maintenance work period of the facility 1B1 required for the maintenance work from the maintenance history information of the facility 1B1 (step S103).

[0035] Note that the operation period calculation unit 32 may predict the maintenance operation period of the facility 1B1 using machine learning from past performance data. The past performance data is, for example, data that associates past maintenance history information and lead time information.

[0036] Next, the maintenance timing setting unit 33 acquires the lead time information of the facility 1B1 from the failure prediction DB 24 of the symptom detection unit 20. Further, the maintenance timing setting unit 33 acquires the time-series prediction information of the inventory quantity of parts in the process B from the inventory quantity transition prediction DB 45 of the production planning unit 40.

[0037] Next, the maintenance timing setting unit 33 refers to the lead time information of the facility 1B1, the time-series prediction information of the inventory quantity of parts in the process B, and the maintenance operation period information of the facility 1B1. Then, the maintenance timing setting unit 33 determines whether it is possible to set the maintenance timing of the facility 1B1 so that the inventory quantity of parts in the process B does not become less than a predetermined threshold within the lead time of the facility 1B1 and within the maintenance operation period of the facility 1B1 (step S104). Here, the aforementioned predetermined threshold is, for example, zero, but is not limited to zero and can be set respectively.

[0038] When the maintenance timing setting unit 33 can set the maintenance timing of the facility 1B1 (YES in step S104), it completes the setting of the maintenance timing (step S105). Here, since the production of the facility 1B1 stops during the maintenance operation period of the facility 1B1, the inventory quantity of parts in the process B continues to decrease. If the inventory quantity of parts in the process B becomes insufficient, a line stop will occur in the process C, which is the subsequent process of the process B. In order to suppress the line stop in the process C, the maintenance timing setting unit 33 sets the maintenance timing of the facility 1B1 so that the inventory quantity of parts in the process B does not become insufficient within the maintenance operation period of the facility 1B1 within the lead time of the facility 1B1. By doing so, the maintenance timing setting unit 33 can minimize the line stop in the process C, which is the subsequent process of the process B.

[0039] On the other hand, when the maintenance time setting unit 33 cannot set the maintenance time of the facility 1B1 (NO in step S104), it temporarily sets the maintenance time of the facility 1B1 (step S106). For example, the maintenance time setting unit 33 temporarily sets the maintenance time of the facility 1B1 so that the amount by which the inventory of parts in process B during the maintenance work period falls below a predetermined threshold is minimized. Then, the maintenance time setting unit 33 instructs the production plan making unit 42 of the production planning department 40 to revise the production plan.

[0040] When the production plan making unit 42 receives an instruction to revise the production plan, it revises the production plan on the production line (step S107). Specifically, the production plan making unit 42 increases the production volume of parts in process B during a predetermined period within the production capacity range of process B so that the inventory of parts in process B during the maintenance work period does not fall below a predetermined threshold. Also, the production plan making unit 42 decreases the production volume of parts in process C, which is the subsequent process of process B, during a predetermined period to such an extent that the efficiency does not fall below a certain value so that the inventory of parts in process B during the maintenance work period does not fall below a predetermined threshold.

[0041] When the production plan making unit 42 still cannot prevent the inventory in process B from falling below the predetermined threshold even after making the above-described revisions, it instructs the maintenance time setting unit 33 of the maintenance planning department 30 to revise the maintenance plan. When the maintenance time setting unit 33 receives an instruction to revise the maintenance plan, it revises the maintenance time in process B or process C. Specifically, the maintenance time setting unit 33 delays the maintenance time of each facility 1B in process B. Also, the maintenance time setting unit 33 advances the maintenance time of each facility 1C in process C, which is the subsequent process of process B.

[0042] Therefore, even when the maintenance time setting unit 33 temporarily sets the maintenance time of the facility 1B1, by revising the production plan information or revising the maintenance plan information, it is possible to minimize the line stoppage in process C, which is the subsequent process of process B.

[0043] As described above, when formulating a maintenance plan for the facility 1B1, for example, the maintenance plan formulation system 100 according to the first embodiment sets the maintenance timing of the facility 1B1 within the lead time of the facility 1B1 based on the temporal change in the inventory level of parts in process B. For example, the maintenance plan formulation system 100 can set the maintenance timing of the facility 1B1 during a period when the inventory level of parts in process B does not run short. Therefore, the maintenance plan formulation system 100 can minimize the stoppage of the line in process C, which is the subsequent process.

[0044] <Hardware Configuration> Subsequently, with reference to FIG. 3, a hardware configuration example of a computer 1000 that realizes each component (the logistics and production status monitoring unit 10, the sign detection unit 20, the maintenance plan unit 30, and the production plan unit 40) in the maintenance plan formulation system 100 will be described. In FIG. 3, the computer 1000 has a processor 1001 and a memory 1002. The processor 1001 may be, for example, a microprocessor, an MPU (Micro Processing Unit), or a CPU (Central Processing Unit). The processor 1001 may include a plurality of processors. The memory 1002 is composed of a combination of a volatile memory and a non-volatile memory. The memory 1002 may include a storage arranged separately from the processor 1001. In this case, the processor 1001 may access the memory 1002 via an I / O interface (not shown).

[0045] Also, each component in the above-described embodiment is configured by hardware or software, or both, and may be configured by one piece of hardware or software, or may be configured by a plurality of pieces of hardware or software. The functions (processes) of each component in the above-described embodiment may be realized by a computer. For example, a program for performing the method in the embodiment may be stored in the memory 1002, and each function may be realized by the processor 1001 executing the program stored in the memory 1002.

[0046] These programs include a set of instructions (or software code) that cause a computer to perform one or more of the functions described in the embodiments when loaded into the computer. The program may be stored in a non-transitory computer-readable medium or a tangible storage medium. By way of example and not limitation, a computer-readable medium or a tangible storage medium includes random-access memory (RAM), read-only memory (ROM), flash memory, solid-state drive (SSD), or other memory technologies, CD-ROM, digital versatile disc (DVD), Blu-ray (registered trademark) disc, or other optical disc storage, magnetic cassette, magnetic tape, magnetic disk storage, or other magnetic storage devices. The program may also be transmitted on a transitory computer-readable medium or a communication medium. By way of example and not limitation, a transitory computer-readable medium or a communication medium includes electrical, optical, acoustic, or other forms of propagated signals.

[0047] Note that the present invention is not limited to the above embodiments and can be appropriately modified without departing from the spirit of the invention.

Explanation of Reference Numerals

[0048] 1 Facility 2 Parts Transport Vehicle 10 Logistics and Production Status Monitoring Unit 11 Logistics and Production Status DB 20 Symptom Detection Unit 21 Failure History DB 22 Facility Monitoring Unit 23 Failure Prediction Unit 24 Failure Prediction DB 30 Maintenance Planning Unit 31 Maintenance History DB 32 Working Period Calculation Unit 33 Maintenance Time Setting Unit 40 Production Planning Unit 41 Higher-Level Planning and Demand Prediction DB 42 Production Plan Generation Unit (Production Plan Revision Unit) 43 Production Plan DB 44 Inventory Quantity Prediction Section 45 Inventory Quantity Trend Prediction DB 100 Maintenance Plan Formulation System 1000 Computer 1001 Processor 1002 Memory

Claims

1. a failure prediction unit that predicts a grace period until a piece of equipment fails based on equipment information of the equipment used in a target process among a plurality of processes included in the production line; an inventory quantity prediction unit that predicts, based on production plan information for the production line, a time transition of an inventory quantity of parts that are processed in the target process and supplied to a process subsequent to the target process; a maintenance timing setting unit that sets a maintenance timing for performing maintenance work on the equipment within the grace period based on a time transition of the inventory amount of the parts; a work period calculation unit that calculates a maintenance work period required for the maintenance work of the facility, The maintenance timing setting unit and setting the maintenance timing within the grace period so that the inventory amount of the part does not become equal to or less than a predetermined threshold value within the maintenance work period. Maintenance planning system.

2. a production plan correction unit that corrects the production plan information when the maintenance timing cannot be set within the grace period so that the inventory amount of the part does not become equal to or less than a predetermined threshold within the maintenance work period, The maintenance planning system according to claim 1 .

3. The production plan correction unit modifying the production plan information by at least one of increasing the production volume of parts in the target process during a predetermined period and decreasing the production volume of parts in the subsequent process during a predetermined period; The maintenance planning system according to claim 2 .

4. The inventory quantity prediction unit If an abnormality occurs in the downstream process, updating the time transition of the inventory amount of the part based on the status of the abnormality. The maintenance planning system according to any one of claims 1 to 3.

5. predicting a grace period until a piece of equipment used in a target process among a plurality of processes included in a production line based on equipment information of the equipment; predicting, based on production plan information for the production line, a time transition of inventory amounts of parts processed in the target process and supplied to a process subsequent to the target process; The computer executes setting a maintenance timing for performing maintenance work on the equipment within the grace period based on the change in the inventory amount over time, and further Calculating a maintenance work period required for the maintenance work of the equipment; The computer executes, within the grace period, setting the maintenance timing so that the inventory amount of the part does not become equal to or less than a predetermined threshold during the maintenance work period. Conservation planning methods.

6. Among a plurality of processes included in a production line, a process of predicting a remaining period until the equipment fails based on equipment information of the equipment used in a target process; a process of predicting a temporal change in the inventory level of parts processed in the target process and supplied to a subsequent process of the target process based on production plan information in the production line; a process of setting a maintenance timing for performing maintenance work on the equipment within the remaining period based on the temporal change in the inventory level, and causing a computer to execute the processes; further, calculating a maintenance work period required for the maintenance work of the equipment; causing the computer to set the maintenance timing so that the inventory level of the parts does not fall below a predetermined threshold within the maintenance work period within the remaining period. Program.

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