Production instruction support system, production instruction support method

Abstract

To easily determine whether a work performed at a site is a work having no operational problem or an effective work, when the work performed at the site is different from a production plan.SOLUTION: Operation information including 4M data related to production obtained when predetermined site work is performed is received from a data-generating device used at a production site; the operation information is accumulated in a database for each task performed at the production site; a difference between a procedure of a predetermined production plan and the operation information accumulated in the database is analyzed; as a result of the analysis, difference data including a changed task event and a factor causing the task event is output for each task; as a result of the analysis, the difference data is output to a screen of a computer to present the difference data to a user.SELECTED DRAWING: Figure 10

Description

Technical Field

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

Background Art

[0002] Conventionally, various masters that define the operations at the production site are generated at the production preparation stage. For the production line, instruction information for various facilities is generated from this master, and production is carried out using this instruction information. Although workers at the production site are daily improving the operations on-site, as a result of improvements made during the operations, change information such as changes in equipment parameters and improvements to jigs is rarely reflected in the master generated at the production preparation stage. Therefore, differences may occur between the production plan using the unreflected master and the production results obtained using the equipment parameters and jigs improved on-site.

[0003] In view of such problems, a technique for giving production instructions to workers while considering differences in equipment parameters and jig settings between the site and the plan, or between devices and factories, has been disclosed (for example, Patent Document 1). Patent Document 1 describes an information processing apparatus for supporting production instructions at a manufacturing site, including a data extraction unit that acquires performance data including Man data from the manufacturing site, and a work candidate calculation unit that estimates the current work situation using a work model in which the performance data is associated with the work content at the manufacturing site.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Patent Document 1 estimates the current work situation using a work model that associates actual data, including man data obtained from the manufacturing site, with the actual work performed at the manufacturing site. However, when comparing the production plan with the work performed at the actual site, if the work performed at the site differs from the production plan, it is difficult to determine whether the work performed at the site is operationally acceptable or effective.

[0006] The present invention aims to provide a technology that makes it possible to easily determine whether work performed on-site is operationally acceptable or effective, even when the work performed on-site differs from the production plan. [Means for solving the problem]

[0007] The production instruction support system according to the present invention is a production instruction support system that supports production instructions at a production site using a computer having a processor and memory, wherein the processor receives operational information including 4M data related to production obtained when a predetermined on-site operation is performed from a data generation device used at the production site, stores the operational information in a database for each operation performed at the production site, analyzes the difference between the predetermined production plan procedure and the operational information stored in the database, outputs difference data for each operation including the changed operation event and the factors that caused the operation event as a result of the analysis, and displays the difference data on the computer screen as a result of the analysis to the user. [Effects of the Invention]

[0008] According to the present invention, when work performed on-site differs from the production plan, it is possible to easily determine whether the work performed on-site is operationally acceptable and effective. Other issues, configurations, and effects will be clarified by the following description of embodiments for carrying out the invention. [Brief explanation of the drawing]

[0009] [Figure 1] This figure shows an example of the configuration of the production instruction support system in this embodiment. [Figure 2] This diagram shows an example configuration for a production information management server. [Figure 3A] Figure 2 shows an example of a business information database. [Figure 3B] Figure 2 shows an example of a business-related element information database. [Figure 3C] Figure 2 shows an example of an event cause estimation information database. [Figure 3D] Figure 2 shows an example of a database for authorization to implement on-site changes. [Figure 4] This figure shows an example of the information stored in the data type included in the equipment operation information DB, which is obtained by converting the 4M data processed by this system into a predetermined format. [Figure 5] This diagram shows an example of a production process from raw materials to finished product. [Figure 6] This diagram shows an example configuration for a production information management terminal. [Figure 7] This diagram shows an example configuration of a business information collection terminal. [Figure 8] This figure shows an example of a device operation information database. [Figure 9] This sequence diagram shows the processing flow from the time of creation to the storage of 4M data in this system. [Figure 10] Figure 9 is a sequence diagram showing the processing flow to determine the validity of the work procedure using the data collected. [Figure 11] This flowchart shows the processing procedure for factor estimation in S1006. [Figure 12] The figure in S1006 and S1007 shows an example of the results of the above estimation. [Figure 13] This figure shows an example of differential data. [Modes for carrying out the invention]

[0010] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The following description and drawings are examples for explaining the present invention, and for the sake of clarity of explanation, appropriate omissions and simplifications have been made. The present invention can be implemented in various other forms. Unless otherwise limited, each component may be singular or plural.

[0011] In the drawings, the positions, sizes, shapes, ranges, etc. of the respective components shown may not represent the actual positions, sizes, shapes, ranges, etc. in order to facilitate understanding of the invention. Therefore, the present invention is not necessarily limited to the positions, sizes, shapes, ranges, etc. disclosed in the drawings.

[0012] In the following description, various information may be described using expressions such as "database", "table", "list", etc., but the various information may be represented by other data structures. In order to indicate that it does not depend on the data structure, "XX table", "XX list", etc. may be referred to as "XX information". When explaining identification information, when expressions such as "identification information", "identifier", "name", "ID", "number", etc. are used, these can be replaced with each other.

[0013] When there are a plurality of components having the same or similar functions, they may be described by attaching different subscripts to the same reference numeral. However, when it is not necessary to distinguish these plurality of components, the subscripts may be omitted in the description.

[0014] In the following description, there may be cases where the processing performed by executing a program is described. However, the program is executed by a processor (e.g., a CPU, a GPU (Graphics Processing Unit)), and in order to perform the defined processing while appropriately using a storage resource (e.g., a memory) and / or an interface device (e.g., a communication port), etc., the subject of the processing may be the processor. Similarly, the subject of the processing performed by executing the program may be a controller, a device, a system, a computer, or a node having a processor. The subject of the processing performed by executing the program only needs to be an arithmetic unit, and may include a dedicated circuit (e.g., an FPGA (Field-Programmable Gate Array) or an ASIC (Application Specific Integrated Circuit)) that performs a specific processing.

[0015] The program may be installed from a program source into a device such as a computer. The program source may be, for example, a program distribution server or a storage medium readable by a computer. When the program source is a program distribution server, the program distribution server includes a processor and a storage resource for storing the program to be distributed, and the processor of the program distribution server may distribute the program to be distributed to other computers. Also, in the following description, two or more programs may be realized as one program, or one program may be realized as two or more programs.

Example

[0016] Hereinafter, an example of a production instruction support system and a production instruction support method according to this example will be described.

[0017] Figure 1 shows an example of the configuration of the production instruction support system in this embodiment. The production instruction support system 1000 in this embodiment includes a production information management server 1 located in the operation management center 7, a production information management terminal 2 operated by the system administrator, business information collection terminals 3 (3-1 to 3-M) located at one or more locations 5 (5-1 to 5-M) such as factories, and one or more data generators 4 (4-11 to 4-13, 4-M1 to 4-M2) connected to the business information collection terminals 3, all of which are connected to each other via a network 6. The number of business information collection terminals 3 and data generators 4 can be arbitrarily determined according to the environment in which this system is applied. The data generator 4 is, for example, a robotic arm that performs various operations (such as sorting and packaging) on ​​items being transported on a line in a factory that serves as the production site. The data generator 4 outputs information regarding the control amount when various operations for work are performed (for example, business performance data such as the amount of rotation of the arm and the direction of the arm at each time) to the business information collection terminal 3. The business information collection terminal 3 aggregates the information regarding the control quantities received from the data generation device 4 under its control and transmits it to the production information management server 1.

[0018] Figure 2 shows an example configuration of the production information management server 1. As shown in Figure 2, the production information management server 1 has a network interface (I / F) 10, a control unit (CPU) 12, an external storage device 14, and an internal storage device 16, all connected via a bus 18.

[0019] Network I / F10 is an interface for connecting to other devices via network N.

[0020] The CPU 12 is a processor that performs the processing necessary for this system by executing programs stored in the internal memory device 16.

[0021] The external storage device 14 is a storage device that stores various data used in the processing of this system. As shown in Figure 2, the external storage device 14 stores the business information DB (Data Base) 163, the business-related element information DB 165, the event cause estimation information DB 167, and the field change implementation authority DB 169. The specific contents of these will be described later.

[0022] The internal storage device 16 is a memory that stores programs for executing the system's processes and intermediate data that is temporarily used when the programs are executed. As shown in Figure 2, the internal storage device 16 stores the production information management program 161. The specific operations performed by the production information management program 161 will be described later.

[0023] Figure 3A shows an example of the business information DB163 shown in Figure 2. The business information DB163 is a database that stores the procedures of operations, including production processes, performed on the production site in chronological order. As shown in Figure 3, the business information DB163 stores the following in association: a node identifier for identifying the production site location, the name of the operations performed at the location identified by the node identifier, a business-related element list which is a list of 4M data used in the operations, a business item list which shows the procedures of the operations with the business name, and a business performance data pointer which indicates the location where business performance data containing information about the controlled quantities when the operations for the procedures were performed is stored. The business performance data includes not only the controlled quantities but also the time and duration of the operations. 4M data refers to data related to the four elements (4M: Human, Machine, Material, Method) necessary for properly performing quality control operations on the production site.

[0024] The node identifier stores an identification number such as "N0001" to identify a location, the task name stores "Assembly of Part B", and the task-related element list "R0001~R000N" for "Assembly of Part B" is stored. Furthermore, the task item list "L0001~L000M" for the relevant task is stored, and the actual work performance data for each task stored in the task item list, "April 1, 2022 12:00:00 - April 1, 2022 12:00:10:10 (L001), April 1, 2022 12:01:00 - April 1, 2022 12:01:20:20 (L0002), April 1, 2022 12:02:00 - April 1, 2022 12:02:30:30 (L0003)... April 1, 2022 12:03:00 - April 1, 2022 12:03:M0:M0 (L000M)", is stored along with the access point for accessing the data.

[0025] In this example, four steps, L0001 to L0004, are stored to assemble part B, and in each step, for example, a list of business-related elements "R0001 to R000N" is stored, corresponding to each step from L0001 to L0004.

[0026] Figure 3B shows an example of the business-related element information DB165 shown in Figure 2. The business-related element information DB165 is a database that stores the specific items of business-related elements stored in the business-related element list corresponding to the business item list in chronological order. In this case, 4M data is stored as business-related elements. As shown in Figure 3B, the business-related element information DB165 stores business-related element IDs, business-related element names identified by the business-related element ID, and specific business-related items 1 to N that constitute the element of the business-related element name in association with each other.

[0027] The business-related element ID stores an identification number such as "R0001," similar to that in the business information DB163, and the business-related element name stores "Procedure ID: S002," with "Work Start Time" as business-related item 1 and "Work End Time" as business-related item N, which constitute the elements of the business-related element name. These times can be obtained from equipment operation data as described later. For example, if an operation on the business information collection terminal 3 or data generation device 4 (for example, if a touch operation on a touch panel connected to these terminals or devices is detected, the time of the touch operation can be obtained as "Work Start Time" and "Work End Time." Here, we have used huMan data as an example from the 4M data, but the same considerations apply to Machine data. For example, if the operation of "Procedure ID: S002" is performed using machine A, the "Start Time" and "Stop Time" of machine A become Machine data, and these are set as the start time and end time of the operation in business-related items 1 and 2. For Material data, for example, "Part C, Part D, Part E," which shows the configuration of part B assembled by machine A, can be stored as a business-related item, associated with the business-related element name "Part B assembled by machine A (Material)." Also, for Method data among the 4M data, for example, "Joining process of part C and part D, and attaching process of part E to part after the joining process," which shows the process of assembling part B by machine A, can be stored as a business-related item, associated with the business-related element name "Method for assembling part B using machine A (Method)."

[0028] Figure 3C shows an example of the event cause estimation information DB167 shown in Figure 2. The event cause estimation information DB167 is a database that stores information for estimating the cause of changes in the on-site environment and procedures for performing the business name of the business in the business information DB163 shown in Figure 3A. As shown in Figure 3C, the event cause estimation information DB167 stores the event identifier, the business event identified by the event identifier, the event determination method that indicates the conditions for determining the business event, and the content of the on-site environment and procedures that were actually changed, in association with each other. The event cause estimation information DB167 is registered and updated in the factor estimation process (Figure 11) described later.

[0029] The event identifier is stored as an identification number such as "P0001," the event for the business is described as "change in the position of data generator 4 that assembles part B," the method for determining the event for the business is described as "the position of data generator 4 has been moved by a certain distance (1 meter) or more," and the positions of data generator 4 before and after the actual movement (before movement: position A, after movement: position B) are stored as site change 1 and site change N, respectively. Actual site changes can be realized, for example, by analyzing images including data generator 4 captured by multiple cameras installed near the site. In this example, the event for the business is described as the case where the position of data generator 4 is moved, but it may also include content that changes the order of work processes, such as "change in business flow" or "change in business items."

[0030] Figure 3D shows an example of the on-site change implementation authority DB169 shown in Figure 2. The on-site change implementation authority DB169 is a database that stores the authority to perform the business events defined in the event cause estimation information DB167 shown in Figure 3C. As shown in Figure 3D, the on-site change implementation authority DB169 stores on-site changes defined as business events and the authorized implementers who have the authority to perform those on-site changes in association with each other.

[0031] A site change, for example, similar to the events in the above-mentioned tasks, is recorded as "a change in the position of data generation device 4 for assembling part B," and the authorized person for implementation is recorded as "site supervisor A, worker." In other words, this indicates that the site change is authorized by both site supervisor A and the worker in charge. The site change implementation authorization DB169 is predetermined by the administrator of this system.

[0032] Figure 4 shows an example of information stored in the data type included in the equipment operation information DB363 (described later), which converts the 4M data processed by this system into a predetermined format. As shown in Figure 4, data type 401 includes a label for the business that output the 4M data, a process ID to identify which process the business identified by the label belongs to, a worker ID to identify the worker (huMan) performing the business in that process, a component ID_input to identify the component (Material) to be input in the business in that process, a component ID_output to identify the component (Material) to be output in the business in that process, a machine ID to identify the machine (Machine) used in the business in that process, a procedure ID to identify the procedure (Method) for performing the business in that process, a preceding business ID to identify the business preceding the business in that process, and a succeeding business ID to identify the business succeeding the business in that process.

[0033] Figure 4 shows the 4M data obtained when the procedure with procedure ID "S002" was performed, which is part of the work procedure that constitutes task A, identified by process ID "P002". This procedure indicates that the worker identified by worker ID "H002" input a part identified by part ID_input "Met001", performed the work using the machine identified by machine ID "M002", and output a part identified by part ID_output "Met002". It also indicates that the preceding task of task A is the task identified by preceding task ID "P001", and the succeeding task of task A is the task identified by subsequent task ID "P003". The 4M data actually transmitted from the data generator 4 includes information included in the data types described above, as well as information regarding the control amounts of various operations for the work performed by the data generator 4.

[0034] Figure 5 shows an example of a production process from raw materials to finished products. As shown in Figure 5, in production process 501, from raw materials as input to finished products as output, a certain material is input, task A is performed and part A is output, and in the next task B, part A is input and part B is output. Furthermore, part B is used as input for tasks C and E, and parts C and E are output. Furthermore, in the next task D, part C is input and part D is output, and in task F, part E is input and part F is output. Finally, in task G, parts E and F are input and the finished product is output. In each of tasks A to G that make up this production process, the 4M data shown in Figure 4 is transmitted from the data generator 4 via the task information collection terminal 3. This system grasps whether the work performed in each of these tasks was done according to instructions, or if not, how the procedure was changed, and if improvements can be made, the previous procedure is changed and the improved procedure is quickly reflected.

[0035] Figure 6 shows an example configuration of the production information management terminal 2. As shown in Figure 6, the production information management terminal 2 has a network interface (I / F) 20, an input / output device 21, a control unit (CPU) 22, an external storage device 24, and an internal storage device 26, all connected via a bus 28.

[0036] Network I / F20 is an interface for connecting to other devices via network N.

[0037] The input / output device 21 includes input devices (e.g., keyboard and mouse) for inputting various information necessary for this system, and output devices (e.g., display device) for displaying and outputting the information input by the input devices and various information output by this system.

[0038] The CPU 22 is a processor that performs the necessary processing for this system by executing programs stored in the internal memory device 26.

[0039] The external storage device 24 is a storage device that stores various data used in the processing of this system. For example, the external storage device 24 stores information that is input and output from the input / output device 21.

[0040] The internal storage device 26 is a memory that stores programs for executing the system's processes and intermediate data that is temporarily used when the programs are executed. As shown in Figure 6, the internal storage device 26 stores the production information operation program 261. The specific operations performed by the production information operation program 261 will be described later.

[0041] Figure 7 shows an example configuration of the business information collection terminal 3. As shown in Figure 7, the business information collection terminal 3 has a network interface (I / F) 30, a control unit (CPU) 32, an external storage device 34, and an internal storage device 36, all connected via a bus 38.

[0042] Network I / F30 is an interface for connecting to other devices via network N.

[0043] The CPU 32 is a processor that performs the necessary processing for this system by executing programs stored in the internal memory device 36.

[0044] The external storage device 34 is a storage device that stores various data used in the processing of this system. As shown in Figure 7, the external storage device 34 stores the equipment operation information DB 363. The equipment operation information DB 363 will be described later with reference to Figure 8.

[0045] The internal storage device 36 is a memory that stores programs for executing the system's processes and intermediate data that is temporarily used when the programs are executed. As shown in Figure 7, the internal storage device 36 stores the business performance information management program 361. The specific operations performed by the business performance information management program 361 will be described later.

[0046] Figure 8 shows an example of the Equipment Operation Information DB363. The Equipment Operation Information DB363 is data that is collected by aggregating the 4M data transmitted from the data generator 4, converting it into a predetermined format, and storing it as history for a certain period (for example, one day). As shown in Figure 8, the Equipment Operation Information DB363 stores the following information in association with each other: the location identifier where the data generator 4 is installed, the device identifier to identify the data generator 4, the date and time of data recording when the 4M data received from the data generator 4 is recorded, the data type (information to identify the contents of huMan, Machine, Material, Method), and the operation data, which is the actual business performance data indicated by the data type.

[0047] The location identifier stores an identification number such as "S0001," the device identifier stores the identifier of data generator 4, "A0001," and the data recording date and time stores "April 1, 2022, 17:00:00." In addition, the data type stores information to identify the content of the 4M data shown in Figure 4, and the operation data stores operational performance data such as information on the control amount when data generator 4 actually performed the work.

[0048] Figure 9 is a sequence diagram showing the processing flow up to the storage of 4M data performed in this system. Below, we will illustrate with an example using data generators 4-11 and 4-12 and business information collection terminal 3-1, but the same processing is performed for the other data generators 4 and business information collection terminals 3.

[0049] As shown in Figure 9, data generators 4-11 to 4-12 perform operations in predetermined work processes (S901, S903) and transmit the 4M data obtained during these operations to the business information collection terminal 3-1 (S902, S904).

[0050] The business information collection terminal 3-1 aggregates and converts the 4M data received from data generators 4-11 to 4-12 into the format of the equipment operation information DB363 shown in Figure 8 (S905, S907), and transmits the converted equipment operation data to the production information management server 1 (S906, S908).

[0051] The production information management server 1 reads the equipment operation data received from the business information collection terminal 3-1 and records it in the business information DB 163 and the business-related element information DB 165 (S909). For example, the production information management server 1 sets the site identifier stored in the equipment operation data as the node identifier in the business information DB 163. The production information management server 1 also sets the business name in the business information DB 163 to the label stored in the data type of the equipment operation data, sets the name of the data type of the equipment operation data (for example, the item name of the data type) in the business-related element list, and sets the procedure ID of the equipment operation data and the procedure IDs of procedures lower than the procedure identified by the procedure ID in the business item list. Furthermore, the production information management server 1 sets the operation data of the equipment operation data (or the address where the operation data is stored on the server) in the business performance data pointer. The lower procedure IDs are set as business item IDs 1 to N in the business information DB 163.

[0052] Furthermore, the production information management server 1 reads the data type items stored in the business-related element list of the business information DB 163 and sets the 4M data elements included in the data type items shown in Figure 4 (for example, Procedure ID: S002) as the business-related element name. At this time, a business-related element ID (for example, "R0001") is assigned in association with the set business-related element name. Furthermore, the production information management server 1 sets the operation data (for example, the start time and end time of the work for Procedure ID: S002) in association with the set business-related element name (for example, Procedure ID: S002) as business-related items (for example, business-related items 1 and 2).

[0053] Once processing S909 is complete, the latest business information DB163 and business-related element information DB165 will be generated each time equipment operation data is received.

[0054] Figure 10 is a sequence diagram showing the process flow for determining the validity of the work procedure using the data collected in Figure 9. This sequence can be performed at any time.

[0055] As shown in Figure 10, the production information management terminal 2 receives a work procedure confirmation operation from the administrator and sends a work procedure confirmation request to the production information management server 1 (S1001). The work procedure confirmation request includes identification information (e.g., the name of the work) to identify the work to be confirmed.

[0056] The production information management server 1 reads from the business information DB 163 business information data that has a business name matching the identification information included in the work procedure confirmation request received from the production information management terminal 2. Furthermore, the production information management server 1 reads from the business related element information DB 165 business related element data that matches the business related element list of the read business information data. Furthermore, it determines whether there is a difference with the work procedure of a predetermined business (S1002), and if there is a difference, it sends the difference to the production information management terminal 2 (S1003).

[0057] The work procedures for tasks predetermined in the production plan are, for example, for "Task A," if there are "Procedures 1 to 3," the expected allowable work time (time from the expected start time to the expected end time) for each procedure is stored in the production information management server 1. Therefore, the production information management server 1 compares the predetermined work procedures with the data read in S1002 and outputs difference data between the two. This difference data has items such as those shown in Figure 13. In Figure 13, the difference data for on-site work is associated with the task identifier, the task event that has changed from the production plan, the change in on-site work that caused the task event, and the method for determining the task event that has changed.

[0058] The business identifier is the business name or the business ID corresponding to the business name included in the work procedure confirmation request requested in S1001. The business ID is stored together with the business name stored in business information DB163.

[0059] Business events and on-site changes are the results of analyzing the difference data mentioned above. For example, if the analysis shows that the allowable work time for business A is shorter than the expected time when following the predetermined work procedure, then a statement indicating this intention, such as "Processing time for business A has been shortened," will be output. Also, for example, if the analysis of business-related element data used in the business event analysis shows that the machine used is different (for example, the predetermined work procedure uses machine ID "M002," but the business-related element data stores machine ID "M003"), then a statement indicating this intention, such as "Machine change," will be output as an on-site change.

[0060] The method for determining an event outputs the basis for the determination when analyzing a business event. For example, if the analysis shows that the actual work time for task A was shorter than the initially planned allowable work time, the system will output a statement indicating the reason, such as "Actual work time for task A < Planned work time for task A".

[0061] Returning to Figure 10, when the production information management server 1 transmits the above difference to the production information management terminal 2, the production information management terminal 2 displays the difference on its screen (S1004). The screen 1301 that displays the difference is, for example, shown in Figure 13. When the production information management terminal 2 receives confirmation from the administrator, it sends an analysis instruction (including the business identifier shown in Figure 13) to the production information management server 1 to perform the analysis (S1005).

[0062] When the production information management server 1 receives the above analysis instruction from the production information management terminal 2, it estimates the factors causing changes in the work procedure for the business with the business identifier specified in the analysis instruction (S1006). This process (factor estimation process) will be described later using Figure 11. Furthermore, the production information management server 1 transmits the results of the above estimation to the production information management terminal 2 (S1007).

[0063] The production information management terminal 2 displays the results of the estimation received from the production information management server 1 on its screen. The administrator refers to the estimation results and approves (or rejects) the changes in the work procedures (S1008). If approved, the administrator instructs the server to update the business information DB 163 and the business-related element information DB 165 for the business that includes the work procedures whose changes are approved (S1009, S1010). The production information management server 1 updates the business information DB 163 and the business-related element information DB 165 according to the instructions (S1011). The results of the estimation displayed on the screen of the production information management terminal 2 will be described later using Figure 12.

[0064] Figure 11 is a flowchart showing the processing procedure for factor estimation in S1006. As shown in Figure 11, in the factor estimation process, the production information management server 1 refers to the business information DB 163, the business-related element information DB 165, and the predetermined event cause estimation information DB 167 to detect business events that indicate changes in on-site work procedures or the data generator 4 used in the work (S1101). For example, in S1102, the production information management server 1 extracts 4M data of the work procedures or data generator 4 used in the work that match the business identifier output as differential data from the business information DB 163 and the business-related element information DB 165, and analyzes the extracted 4M data to detect signs of change in the work procedures or the data generator 4 used in the work. For example, if the work time for a certain procedure is delayed (or advanced) by more than a certain threshold, the production information management server 1 determines that there are signs of change in the work procedure or the data generator 4 used in the work.

[0065] The production information management server 1 extracts 4M data from the business information DB 163 and the business-related element information DB 165, including changes in the actual work site that indicate changes in the work procedures or data generation devices 4 used in the work, as detected in S1101 (S1102). For example, if the signs detected in S1101 continue for a certain period of time, the production information management server 1 determines that the detected signs are actual changes occurring in the work site. Actual changes occurring in the work site include, for example, changes that are actually occurring in the work procedures or in the data generation devices 4 used in the work. In the case of work procedures, this could include changes in the start and end times of the work procedures, and changes in the work time associated with these changes. In the case of data generation devices 4 used in the work, this could include changes in the location (installation location) of the data generation device 4, or changes in the status of the device such as startup / shutdown, normal / abnormal, etc.

[0066] Furthermore, the production information management server 1 estimates whether there have been any changes to other work procedures and data generators 4 used in other work that are related to the work procedures and data generators 4 used in the work extracted in S1102. If it estimates that there have been changes, it extracts 4M data in which changes to other work procedures and data generators 4 used in other work have been estimated from the business information DB 163 and business-related element information DB 165 (S1103). In S1102, after confirming the signs of the above-mentioned changes in S1101, 4M data including the work procedures and data generators 4 used in the work of the business in which changes have actually occurred were extracted from the business information DB 163 and business-related element information DB 165. However, in S1103, since it is already known what signs indicate that changes have actually occurred, the detection of the above-mentioned signs of change is omitted in this step. Of course, signs of change may also be detected as in S1101.

[0067] To explain S1103 in more detail, the production information management server 1 identifies, for example, the work procedures of the processes before and after the work extracted in S1102, or the work procedures of work similar to the work extracted in S1102, as other related work procedures and data generators 4 used in other work, and estimates that there have been changes in the identified other related work procedures and data generators 4 used in other work. The production information management server 1 extracts the estimated 4M data from the business information DB 163 and the business-related element information DB 165. The work procedures of the processes before and after the work, and the work procedures of similar work, can be stored in the production information management server 1 in advance. By extracting 4M data that estimates changes in other work procedures and data generators 4 used in other work, as in S1103, it becomes possible to predict the impact of similar changes not only for the work procedures and data generators 4 used in work detected in S1101, but also for machines of the same type but with different machine IDs, for example, where the input and output components in the work procedure are the same.

[0068] Then, the production information management server 1 determines the validity of the changes in the work procedures and data generators 4 used in the work extracted in S1102, and the changes in other work procedures and data generators 4 used in other work estimated and extracted in S1103, by determining whether they satisfy the KPIs (Key Performance Indicators) in the production plan (S1105). The KPIs can be stored in advance in the production information management server 1. For example, the allowable lead time for the work procedures in which the above changes have been determined, or the allowable amount of movement of the installation location of the data generators 4, the time range of start / stop timings, etc., are stored in the work procedures in which the above changes have been determined.

[0069] If the production information management server 1 determines that the above-mentioned change is inappropriate (S1105; No), it contacts the worker who made the change to request that they revert the change output in S1102 and S1103 (S1106). The worker's contact information can be stored in the production information management server 1 in advance, for example, by associating it with the worker ID included in the 4M data, such as an email address or phone number.

[0070] If the production information management server 1 determines that the above-mentioned changes are reasonable (S1105; Yes), it further determines whether the changes in other work procedures and data generators 4 used for other work, which were estimated and extracted in S1103, match to a certain extent the changes that are actually occurring in the work procedures and data generators 4 used for work, which were extracted in S1102 (S1107).

[0071] If the production information management server 1 determines that the change estimated in S1103 matches the change extracted in S1102 to a certain extent (S1107; Yes), it outputs difference data as shown in Figure 13, which represents the change estimated in S1103, and also outputs an actual value "1" corresponding to the difference data, indicating that the change was acceptable (S1108). The output of the difference data can be done by applying the method shown in S1002 and S1003 in Figure 10 to the business information data and business-related element data, including the 4M data whose change was estimated in S1103. When the same change as the difference data output in S1108 is repeated, the production information management server 1 adds up the actual value. This makes it possible to determine that a change indicated by difference data with a large actual value is a highly reliable change that has a history of change.

[0072] On the other hand, if the production information management server 1 determines that the changes estimated in S1103 do not match the changes extracted in S1102 to a certain extent (S1107; No), it outputs differential data similar to that in S1108 and registers it in the event cause estimation information DB 167 (S1109). For example, the production information management server 1 sets the business identifier, business event, on-site work change 1 to N, and event determination method items included in the differential data shown in Figure 13 to the event identifier, business event, on-site change 1 to N, and event determination method of the event cause estimation information DB 167 shown in Figure 3C, respectively.

[0073] When either process S1108 or S1109 is completed, the production information management server 1 refers to the on-site change implementation authority DB 169 shown in Figure 3D and determines whether it has the authority to make changes like those in S1102 and S1003 (S1110). The production information management server 1 determines whether it has the authority to make changes like those in S1102 and S1003 (S1110).

[0074] If the production information management server 1 determines that it has the authority to make changes like those in S1102 and S1103 (S1110; Yes), then these changes are permitted, and the process is terminated. On the other hand, if the production information management server 1 determines that it does not have the authority to make changes like those in S1102 and S1103 (S1110; No), then these changes are not permitted, and the server contacts the supervisor of the worker who made these changes (S1111). The method of this contact may be the same as in S1106.

[0075] Figure 12 shows an example of the estimation results in S1006 and S1007. As shown in Figure 12, the estimation result 1201 is associated with the business event that was the subject of the factor estimation process in S1006, and the candidate site change that shows the estimated changes at the site for that business event. The business event and the candidate site change are obtained from the results of analyzing the difference data of business information data including 4M data used to determine changes in the work procedures and data generators 4 used in the work, extracted in S1102, or the difference data of business-related element data including 4M data used to determine changes in other work procedures and data generators 4 used in other work, estimated and extracted in S1103.

[0076] In the upper part of Figure 12, the reason why the "operational data" for the business event "Operational data for transportation equipment for business A and business B cannot be obtained" identified by #1 (sequential number) is not obtainable is likely due to a machine failure. Normally, a machine ID "M002" to identify the machine, as shown in Figure 4, is recorded. Therefore, the production information management server 1 refers to the 4M data and determines that if the machine ID is "-" (null) from a certain point in time, there is a possibility that the machine has failed. The production information management server 1 then outputs "Equipment replacement due to transportation equipment failure" as a candidate response to the change in the field. Regarding what kind of candidate responses to the field change described above should be output, the candidate responses to business events and field changes should be stored in the database in advance by associating them, or candidate responses to business events should be set by performing semantic analysis on responses to business events (Q&A, etc.) shown on various sites.

[0077] Furthermore, as shown in the lower part of Figure 12, the production information management server 1 outputs the data corresponding to (S1107;Yes) and (S1110;Yes) from the business events and proposed on-site changes output in the upper part above as the final on-site change candidates. In this example, the final on-site change candidate for business event #1 (sequential number) is "Version upgrade due to failure of transportation equipment," which has a confidence level of "90%." A confidence level of "90%" indicates the percentage of times (S1107;Yes) was obtained in the judgment process of (S1107). In other words, the possibility that the change estimated in S1103 matches the actual change on-site is high enough that this on-site change candidate is presented as the final candidate. In addition, this on-site change can be modified by the on-site worker in S1110. Therefore, in S1008, the administrator visually inspects the screen and presses the confirmation button. In S1009, the production information management terminal 2 accepts the candidate for the final on-site change and sends an instruction to update the content to that candidate. In S1011, the production information management server 1 updates the business information DB 163, which contains 4M data including business events corresponding to the candidate for the final on-site change, and the business-related element information DB 165, according to the update instruction received from the production information management terminal 2. For example, the production information management server 1 changes the procedure stored in the business item list corresponding to the business-related element list that stores the 4M data to the procedure stored in the candidate for the final on-site change, or changes the equipment used in the procedure stored in the business item list to the equipment after the version upgrade.

[0078] In Figure 11, if the worker does not have the authority to perform the task (S1111; No), the supervisor of the worker is notified. However, if the system repeatedly determines that it is necessary to contact the supervisor beyond a certain number of times, the actual situation on site may take precedence. For example, the worker may be temporarily granted the authority to perform the task, and the process may be terminated by considering that the worker has the authority to perform the task (S1111; Yes). This can reduce the number of notifications sent to the supervisor.

[0079] As described above, in this system, as explained in S1002, S1003, etc. in Figure 10, the production instruction support system 1000, which supports production instructions at the production site using a computer having a processor and memory, receives operational information (e.g., equipment operation information DB363) including 4M data related to production obtained when a predetermined on-site operation (e.g., "assembly of part B") is performed from a data generation device 4 used at the production site. The system stores the operational information in a database (e.g., business information DB163, business-related element information DB165) for each operation performed at the production site. It analyzes the difference between the predetermined production plan procedure and the operational information stored in the database. As a result of this analysis, it outputs difference data (e.g., Figure 13) for each operation, including the changed business event and the factors that caused the business event. As a result of the analysis, it outputs the difference data on the computer screen and presents it to the user. This makes it easy to check improvement proposals for work implemented bottom up at the site. In addition, if a problem occurs at the site, the current situation can be easily checked. Therefore, even if the work performed on-site differs from the production plan, managers will be able to easily determine whether the work performed on-site is operationally acceptable and effective.

[0080] Furthermore, as explained in S1006 in Figure 10 and S1103 in Figure 11, the processor estimates whether or not there has been a change in the business events of business operations that have a predetermined relationship with the business operations that include the business operations in which the changes occurred (for example, business operations in the preceding and succeeding processes of the business operations that include the business operations in which the changes occurred, or business operations with similar work procedures). This makes it possible to predict the impact of similar changes occurring in other business operations that use the same machine as the business operations that produced the differential data.

[0081] Furthermore, as explained in Figure 11, S1107, and Figure 12, the processor outputs the difference data for tasks with the predetermined relationship if the estimated change matches to a certain extent the change when the difference data was output (for example, if the delay between the start and end times of a certain procedure is similar, with an error of less than 1 minute, which is the threshold). This allows the user to check the difference data for other tasks that are similar to the task for which analysis has been instructed.

[0082] Furthermore, as explained in Figure 11, S1107, and Figure 12, the processor determines that changes in business events of the business having a predetermined relationship, which have output the differential data more frequently, are changes that have a history of occurrence, and reflects these past changes in the procedures of the business that include the business events in which the determined changes occurred. This makes it possible to quickly capture changes that occur on-site and update the instruction information held as planned values ​​to match the current situation on-site.

[0083] The present invention is not limited to the embodiments described above, and in the implementation stage, the components can be modified and implemented without departing from the gist of the invention, or the multiple components disclosed in the embodiments can be appropriately combined. [Explanation of symbols]

[0084] 1000 Production Instruction Support System 1. Production Information Management Server 2. Production Information Management Terminal 3. Business Information Collection Terminal 4. Data Generator 5 locations 6 Network 7. Operations Management Center

Claims

1. A production instruction support system that uses a computer having a processor and memory to support production instructions in a production site, The aforementioned processor, The system receives operational information, including 4M data related to production, obtained from data generation devices used in the production site when a predetermined on-site task is performed. The aforementioned operational information is stored in a database for each task performed at the production site. The system analyzes the difference between the predetermined production plan procedures and the operational information stored in the database, and outputs difference data for each task, including the changed business events and the factors that caused those business events, based on the results of the analysis. As a result of the analysis, the difference data is output to the computer screen and presented to the user. When estimating whether or not there has been a change in the business events of a business that has a predetermined relationship with a business that includes the business events in the differential data that have undergone the aforementioned changes, If the estimated change matches to a certain extent the change included in the output difference data, the difference data will be output for the business operations that have the predetermined relationship. A production instruction support system characterized by the following features.

2. The processor is Changes in business events of the aforementioned business that have a predetermined relationship and have been output more frequently are judged to be highly reliable changes. The procedures for the business operations, including the business events in which the aforementioned changes were determined, are to reflect the aforementioned highly reliable changes. The production instruction support system according to feature 1.

3. A production instruction support method performed in a production instruction support system that supports production instructions at a production site using a computer having a processor and memory, The system receives operational information, including 4M data related to production, obtained from data generation devices used in the production site when a predetermined on-site task is performed. The aforementioned operational information is stored in a database for each task performed at the production site. The system analyzes the difference between the predetermined production plan procedures and the operational information stored in the database, and outputs difference data for each task, including the changed business events and the factors that caused those business events, based on the results of the analysis. As a result of the analysis, the difference data is output to the computer screen and presented to the user. When estimating whether or not there has been a change in the business events of a business that has a predetermined relationship with a business that includes the business events in the differential data that have undergone the aforementioned changes, If the estimated change matches to a certain extent the change included in the output difference data, the difference data will be output for the business operations that have the predetermined relationship. A production instruction support method characterized by the following features.

4. The more times the differential data has been output, the more reliable the change is determined to be in the business event of the business having the predetermined relationship. The procedures for the business operations, including the business events in which the aforementioned changes were determined, are to reflect the aforementioned highly reliable changes. The production instruction support method according to feature 3.

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