Maintenance planning system, maintenance planning 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 the maintenance work.SOLUTION: A maintenance planning system 100 according to the present disclosure comprises a failure prediction unit 23, a production stoppage period prediction unit 12, 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 production stoppage prediction unit 12 predicts a production stoppage period in which component production in the target process is stopped, on the basis of conditions of processes preceding the targe process. The maintenance time setting 33 sets a maintenance time at which maintenance work on the equipment should be performed within the grace period and within the production stoppage period.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a maintenance planning system, a maintenance planning method, and a program. [Background technology]

[0002] Patent Document 1 discloses a technology that detects deterioration of parts by monitoring preventive maintenance data of equipment (machines) at a predetermined cycle, and creates a plan for maintenance work (equipment repair, maintenance, etc.) including part replacement work based on the grace period until the part reaches the end of its life. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2017-120618 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, maintenance work is usually performed during non-operating times when the line is stopped. For example, in a line that is constantly operating, maintenance work cannot be performed during non-operating times, and there is a problem that maintenance work in one process requires the line for the subsequent process to be stopped.

[0005] In view of the above problems, the present invention aims to provide a maintenance planning system, a maintenance planning method, and a program that minimize stoppages of downstream process lines due to maintenance work. [Means for solving the problem]

[0006] The maintenance planning system of the present disclosure includes: 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; a production downtime prediction unit that predicts a production downtime period during which production of parts in the target process will be stopped based on the status of a process preceding the target process; and a maintenance timing setting unit that sets a maintenance timing for performing maintenance work on the equipment during the grace period and the production suspension period.

[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 a production stoppage period during which production of parts in the target process will be stopped based on the status of a process preceding the target process; The computer sets a maintenance timing for performing maintenance work on the facility within the grace period and the production suspension period.

[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 of predicting a production stop period during which production of parts in the target process will be stopped based on the status of a process preceding the target process; and setting a maintenance timing for performing maintenance work on the equipment within the grace period and the production suspension period. [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] 1 is a block diagram showing a configuration of a maintenance planning system according to a first embodiment. [Figure 2]3 is a flowchart showing the operation of the maintenance planning system according to the first embodiment. [Figure 3] FIG. 1 is a block diagram showing the configuration of a computer according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, specific embodiments of the present invention will be described in detail with reference to the drawings. In each drawing, the same elements are designated by the same reference numerals, and for clarity of explanation, duplicate explanations will be omitted as necessary.

[0012] (First embodiment) First, the configuration of a maintenance planning system 100 according to the first embodiment will be described with reference to Fig. 1. The maintenance planning system 100 is a system that creates maintenance plans for each piece of equipment 1 used in a plurality of processes (e.g., processes A to C) included in a production line L that produces products. A maintenance plan is a plan for work to adjust equipment and replace parts in order to maintain the equipment in a state where it can operate in perfect condition.

[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 planning system 100 includes a logistics / production status monitor unit 10, a symptom detection unit 20, and a maintenance planning unit 30. The maintenance planning 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 (Database) 11, a production downtime period prediction unit 12, and a production downtime period prediction DB 13. The logistics and production status DB 11 stores the logistics status of parts transported from suppliers or other factories using parts transport vehicles 2 in each process. The logistics and production status DB 11 also stores the production status of parts processed in each process.

[0016] The production downtime prediction unit 12 predicts a production downtime period during which production in a target process will be stopped based on the status of a process preceding the target process that uses equipment 1. The status of the preceding process refers to the production status of parts in the preceding process. In addition, the status of the preceding process refers to the logistics status of parts in the preceding process. The production downtime prediction DB 13 stores predicted production downtime period information.

[0017] The symptom detection unit 20 detects a symptom of a failure in the equipment 1. The symptom 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 piece of equipment 1. The failure history includes, for example, the time when the equipment 1 failed and the details of the failure of the equipment 1.

[0018] 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 values, vibrations, and sounds. The failure prediction unit 23 predicts the period until the equipment 1 reaches the end of its life (hereinafter referred to as the grace period) from the acquired equipment information of the equipment 1. By doing so, the failure prediction unit 23 predicts the timing and scale of a failure of the equipment 1.

[0019] The failure prediction DB 24 stores information predicting the timing and scale of a failure occurring in the equipment 1. For example, the failure prediction DB 24 stores grace period information for the equipment 1.

[0020] The maintenance planning unit 30 formulates a maintenance plan for the facility 1. The maintenance planning unit 30 includes a maintenance history DB 31, a work period calculation unit 32, a maintenance timing setting unit 33, and a maintenance plan DB .

[0021] The maintenance history DB 31 stores maintenance history information of the equipment 1. The maintenance history information is history information of maintenance work carried out in the past on the equipment 1B1.

[0022] The work period calculation unit 32 calculates the period required for maintenance work on the equipment 1 (hereinafter referred to as the maintenance work period) based on the equipment information of the equipment 1. The work period calculation unit 32 also calculates the maintenance work period for the equipment 1 based on the maintenance history information.

[0023] The maintenance timing setting unit 33 sets the timing (hereinafter, maintenance timing) for performing maintenance work on the equipment 1 within the grace period and the production stop period. Specifically, the maintenance timing setting unit 33 sets the maintenance timing so that maintenance work requiring a maintenance work period is completed within the grace period and the production stop period. The maintenance plan DB 34 stores maintenance plan information for each facility 1.

[0024] Next, an example of the operation of the maintenance plan planning system 100 according to the first embodiment will be described with reference to Fig. 2. In the following, an example of the operation of the maintenance plan planning system 100 to plan a maintenance plan for equipment 1B1 used in process B will be described.

[0025] First, equipment monitoring unit 22 of symptom detection unit 20 acquires equipment information of equipment 1B1 used in process B. The equipment information includes, for example, current values, vibrations, and sounds of equipment 1B1. Next, failure prediction unit 23 predicts a grace period until a failure occurs in equipment 1B1 from the equipment information of equipment 1B1 (step S101). Failure prediction unit 23 may also predict the grace period of equipment 1B1 from failure history information acquired from failure history DB 21. Failure prediction DB 24 stores grace period information of equipment 1B1 predicted in process B.

[0026] The failure prediction unit 23 may predict the grace period of the equipment 1B1 using machine learning from past performance data. The past performance data is, for example, data in which past equipment information and grace period information are linked together.

[0027] Next, the production downtime prediction unit 12 of the logistics / production status monitor unit 10 acquires information about the status of the preceding process from the logistics / production status DB 11. The information about the status of the preceding process is, for example, information about the logistics status of parts transported from a supplier or another factory to process B using parts transport vehicle 2. Furthermore, the information about the status of the preceding process is information about the production status of parts in process A, which is the process preceding process B.

[0028] Next, the production downtime period prediction unit 12 predicts a production downtime period during which production of parts in process B will be stopped, based on information about the status of the previous process (step S102). That is, the production downtime period prediction unit 12 predicts a production downtime period in process B from the scale of defects in parts supplied from the previous process to process B. For example, the production downtime period prediction unit 12 predicts a delay from location information of parts transport vehicles 2 that supply parts to process B. In this case, the production downtime period prediction unit 12 predicts a production downtime period in process B from the scale of the delay. Furthermore, the production downtime period prediction unit 12 predicts a shortage in the inventory of parts that are processed in process A and supplied to process B (the inventory of parts in process A) based on the production status of parts in process A. In this case, the production downtime period prediction unit 12 predicts a production downtime period in process B from the scale of the shortage in the inventory of parts in process A. Here, the production downtime period prediction DB 13 stores production downtime period information predicted for process B.

[0029] Next, the work period calculation unit 32 of the maintenance planning unit 30 acquires maintenance history information of the equipment 1B1 from the maintenance history DB 31. The maintenance history information is history information of maintenance work performed on the equipment 1B1 in the past. Next, the work period calculation unit 32 calculates the maintenance work period of the equipment 1B1 required for the maintenance work from the maintenance history information of the equipment 1B1 (step S103).

[0030] The work period calculation unit 32 may calculate the maintenance work period for the equipment 1B1 using machine learning based on past performance data. The past performance data is, for example, data linking past maintenance history information with grace period information.

[0031] Next, the maintenance timing setting unit 33 acquires grace period information for the equipment 1B1 from the failure prediction DB 24 of the symptom detection unit 20. The maintenance timing setting unit 33 also acquires production downtime information for the equipment 1B1 from the production downtime period prediction DB 13 of the logistics / production status monitor unit 10. The maintenance timing setting unit 33 then sets the maintenance timing for the equipment 1B1 so that the maintenance work requiring the maintenance work period is completed within the grace period and the production downtime period (step S104). In this way, the maintenance timing setting unit 33 formulates a maintenance plan for the equipment 1B1 in the process B.

[0032] As described above, when planning a maintenance plan for equipment 1B1, for example, the maintenance plan planning system 100 according to the first embodiment sets the timing of maintenance for equipment 1B1 within the grace period for equipment 1B1 and within the production stop period for process B. Therefore, the maintenance plan planning system 100 can minimize the stoppage of the line in process B due to maintenance work, and can also minimize the stoppage of the line in process C, which is a process subsequent to process B.

[0033] <Hardware configuration> Next, an example of the hardware configuration of a computer 1000 that realizes each component (logistics / production status monitor unit 10, symptom detection unit 20, maintenance planning unit 30) in the maintenance planning system 100 will be described with reference to FIG. 3. 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 multiple processors. The memory 1002 is configured by a combination of volatile memory and non-volatile memory. The memory 1002 may include storage located away from the processor 1001. In this case, the processor 1001 may access the memory 1002 via an I / O interface (not shown).

[0034] Furthermore, each component in the above-described embodiments may be configured by hardware or software, or both, and may be configured by a single piece of hardware or software, or may be configured by multiple pieces of hardware or software. The functions (processing) of each component in the above-described embodiments may be realized by a computer. For example, a program for performing the method in the embodiment may be stored in memory 1002, and each function may be realized by executing the program stored in memory 1002 by processor 1001.

[0035] These programs include instructions (or software code) that, when loaded into a computer, cause the computer to perform one or more functions described in the embodiments. The programs may be stored on a non-transitory computer-readable medium or a tangible storage medium. By way of example and not limitation, computer-readable media or tangible storage media include random-access memory (RAM), read-only memory (ROM), flash memory, solid-state drive (SSD) or other memory technology, CD-ROM, digital versatile disc (DVD), Blu-ray® disc or other optical disk storage, magnetic cassette, magnetic tape, magnetic disk storage or other magnetic storage device. The programs may also be transmitted on a transitory computer-readable medium or communication medium. By way of example and not limitation, transitory computer-readable media or communication media include electrical, optical, acoustic, or other forms of propagated signals.

[0036] The present invention is not limited to the above-described embodiment, and can be modified as appropriate within the scope of the invention. [Explanation of symbols]

[0037] 1 equipment 2 Parts transport vehicles 10 Logistics and Production Status Monitoring Department 11 Logistics and production status DB 12 Production Downtime Prediction Department 13 Production downtime prediction database 20 Symptom detection unit 21 Failure history DB 22 Equipment Monitoring Department 23 Failure Prediction Department 24 Failure prediction database 30 Maintenance Planning Department 31 Maintenance history DB 32 Work period calculation section 33 Maintenance timing setting section 100 Maintenance Planning System 1000 computers 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; a production downtime prediction unit that predicts a production downtime period during which production of parts in the target process will be stopped based on the magnitude of defects in parts supplied to the target process from a process preceding the target process; a maintenance timing setting unit that sets a maintenance timing for performing maintenance work on the equipment during the grace period and the production suspension period, The production downtime prediction unit predicting the magnitude of the delay based on location information of a parts transport vehicle that supplies parts to the target process; predicting a production stoppage period in the target process based on the magnitude of the predicted delay; Maintenance planning system.

2. A failure prediction unit that predicts 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, and a production downtime prediction unit that predicts a production downtime period during which production of parts in the target process will be stopped based on the magnitude of defects in parts supplied to the target process from a process preceding the target process; a maintenance timing setting unit that sets a maintenance timing for performing maintenance work on the equipment during the grace period and the production suspension period, The production downtime prediction unit predicting the size of a shortage in inventory of parts to be processed in the upstream process and supplied to the target process based on the production status of the parts in the upstream process; predicting a production stop period in the target process based on the predicted size of the shortage in inventory of the parts; Maintenance planning system.

3. a work period calculation unit that calculates a maintenance work period required for the maintenance work of the facility, The maintenance timing setting unit The maintenance timing is set so that the maintenance work requiring the maintenance work period is completed within the grace period and the production suspension period. The maintenance planning system according to claim 1 or 2.

4. 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 a production stoppage period during which production of parts in the target process will be stopped based on the magnitude of defects in parts supplied to the target process from a process preceding the target process; a computer executes setting a maintenance timing for performing maintenance work on the equipment within the grace period and the production suspension period; The computer predicting the magnitude of the delay based on location information of a parts transport vehicle that supplies parts to the target process; predicting a production stoppage period in the target process based on the magnitude of the predicted delay; Conservation planning methods.

5. 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 of predicting a production stop period during which production of parts in the target process will be stopped based on the scale of defects in parts supplied to the target process from a process preceding the target process; a process of setting a maintenance timing for performing maintenance work on the equipment within the grace period and the production suspension period; The computer, A process of predicting the magnitude of a delay based on location information of a parts transport vehicle that supplies parts to the target process; and executing a process of predicting a production stop period in the target process based on the magnitude of the predicted delay. program.

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