Component management method, system, and program

Abstract

This component management system (1) is provided with a sensor (11) that detects the state of a consumable component (12) in a facility (10). The system (1) is provided with a control device (30) that determines, on the basis of the state of the consumable component (12), replacement assistance information including the remaining number of uses and a replacement time of the consumable component (12). Furthermore, the system (1) is provided with an output device (60) that outputs the replacement assistance information. The output device (60) includes a display device (61) that outputs the replacement assistance information to a worker. The output device (60) includes a communication device (62) for providing the replacement assistance information to a business entity constituting a supply chain.

Description

Parts management method, system, and program CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on Patent Application No. 2023-218344 filed in Japan on December 25, 2023, and the contents of the original application are incorporated by reference in their entirety.

[0002] The disclosure herein relates to a method, system, and program for managing replaceable parts.

[0003] Patent Document 1 discloses a method, system, and program for automatically ordering parts for a molding machine. The management device in Patent Document 1 automatically predicts when parts for the molding machine will wear out, automatically determines when to order parts based on the predicted wear out times, and automatically processes orders. The contents of the prior art documents are incorporated by reference as explanations of the technical elements in this specification.

[0004] Japanese Patent Application Laid-Open No. 2005-258585

[0005] The technology described in Patent Document 1 forces workers to replace parts when they reach the end of their service life, increasing the burden on the workers. When multiple parts need to be replaced, the burden on the workers increases even more. From the above perspectives and other perspectives not mentioned, further improvements are needed in parts management methods, systems, and programs.

[0006] One disclosed object is to provide a parts management method, system, and program that can provide support information for efficiently replacing parts.

[0007] The parts management system disclosed herein includes consumable parts that are installed in equipment and that are subject to wear, a sensor that detects physical quantities that change in relation to the wear of the consumable parts, and at least one processor, and the processor is equipped with a control device configured to generate replacement assistance information including the remaining amount of the consumable parts and the replacement time when the consumable parts should be replaced based on the physical quantities detected by the sensor, and a display device that displays the replacement assistance information.

[0008] According to the disclosed parts management system, the display device displays the remaining quantity and replacement time. This allows workers to plan and execute replacement work for consumable parts by looking at the display device. As a result, the burden on workers can be reduced.

[0009] The parts management method disclosed herein includes obtaining physical quantities that change in relation to wear from a consumable part that is worn out, generating replacement assistance information based on the physical quantities, the replacement assistance information including the remaining quantity of the consumable part and the replacement time when the consumable part should be replaced, and displaying the replacement assistance information on a display device, and is executed by a control device including at least one processor.

[0010] The parts management program disclosed herein causes a control device including at least one processor to acquire physical quantities that change in relation to wear from consumable parts that are worn out, generate replacement support information including the remaining quantity of the consumable part and the replacement time when the consumable part should be replaced based on the physical quantities, and display the replacement support information on a display device.

[0011] The various embodiments disclosed in this specification employ different technical means to achieve their respective objectives. The reference numerals in parentheses in the claims and in this section are intended to exemplify the correspondence with the following embodiments and are not intended to limit the technical scope. The objectives, features, and advantages disclosed in this specification will become more apparent by reference to the following detailed description and the accompanying drawings.

[0012] FIG. 1 is a block diagram of a parts management system according to a first embodiment. FIG. 2 is a block diagram showing the relationship between the supply chain and the system. FIG. 3 is a flowchart showing a parts management method and a program. FIG. 4 is a plan view showing a display on a display device. FIG. 5 is a block diagram of a parts management system according to a second embodiment. FIG. 6 is a plan view showing a display. FIG. 7 is a block diagram of a parts management system according to a third embodiment. FIG. 8 is a block diagram of a parts management system according to a fourth embodiment. FIG. 9 is a flowchart according to a fifth embodiment. FIG. 10 is a flowchart according to a sixth embodiment. FIG. 11 is a table showing equipment status and display. FIG. 12 is a flowchart according to a seventh embodiment. FIG. 13 is a table showing equipment status and display. FIG. 14 is a flowchart according to an eighth embodiment. FIG. 15 is a table showing equipment status and display. FIG. 16 is a flowchart according to a ninth embodiment. FIG. 17 is a table showing equipment status and display. FIG. 18 is a table showing equipment status and display. FIG. 19 is a flowchart according to an eleventh embodiment. FIG. 20 is a graph showing the limit on the number of uses. FIG. 21 is a flowchart according to an eleventh embodiment.

[0013] Several embodiments will be described with reference to the drawings. In several embodiments, functionally and / or structurally corresponding and / or associated parts may be designated by the same reference numerals or reference numerals that differ in the hundredth or more digits. For corresponding and / or associated parts, reference may be made to the descriptions of other embodiments.

[0014] First Embodiment In FIG. 1 , a parts management system 1 is used in a supply chain including a manufacturing entity that manufactures products using equipment equipped with consumable parts. In the following description, the entity may be a company, organization, group, or individual. Therefore, the manufacturing entity refers to a person that manufactures products. The system 1 is used to implement a method. The system 1 is configured to perform a predetermined function by executing a program stored on a storage medium using a processing circuit. The system 1 is also a system that provides solutions in the manufacturing industry. In the manufacturing industry, production plans, equipment plans, logistics plans, and / or transportation plans vary depending on various factors. The system 1 is used to support the creation of optimized plans under certain constraints, and to create and execute the optimized plans. The system 1 also uses IoT technology to grasp and analyze the status of parts. The system 1 utilizes AI technology as needed. Furthermore, the system 1 provides new value to multiple entities that make up the supply chain, including the manufacturing entity. The AI ​​technology may be provided using machine learning and / or deep learning techniques.

[0015] 1, the system 1 includes a facility 10. The facility 10 is, for example, a processing machine located in a factory or business establishment of a manufacturing entity. The facility 10 may be, for example, a transport machine located in a factory or business establishment of a manufacturing entity. The manufacturing entity manufactures products by processing or transporting workpieces using the facility 10. The facility 10 includes a plurality of mechanical components.

[0016] The multiple mechanical parts include consumable parts 12 provided in the equipment. The consumable parts 12 are parts that wear out. The consumable parts 12 wear out as the consumable parts 12 are used. When the consumable parts 12 are provided in equipment that processes workpieces, the consumable parts 12 are parts that wear out as the workpieces are processed. The wear of the consumable parts 12 can be understood as a wear amount. From the opposite perspective, the wear of the consumable parts 12 can be understood as a remaining unit in which the consumable parts 12 can be used. The remaining unit can be understood as a remaining amount. The unit of the remaining amount is expressed based on various measurement units such as remaining number of times, remaining distance, remaining time, etc. The consumable parts 12 wear out as the number of times the workpieces are processed increases, for example. In this case, the remaining amount of the consumable parts 12 may be expressed as a remaining number of times.

[0017] The consumable parts 12 are mechanical parts that are consumed not only as a reaction to processing, but also in processes related to processing, such as transportation. An example of the consumable parts 12 is a cutting tool used to perform cutting on a product. The consumable parts 12 may be one or more of a variety of parts, such as a cutting tool, a bearing, a conveyor, a vice, or a wiper. In addition to the consumable parts 12, the equipment 10 also includes other parts 13. The other parts 13 may be one or more of many parts other than the consumable parts 12. The other parts 13 may be, for example, a support device that supports the consumable parts 12. The other parts 13 may be, for example, a drive device such as a motor that provides relative movement between the consumable parts 12 and the part being processed.

[0018] In the following description, a case will be described in which the consumable part 12 is a cutting tool. A case will be described in which the other part 13 is a holder that supports the cutting tool. Alternatively, or in addition, the other part 13 may be an electric motor that realizes relative movement between the cutting tool and a product (which may also be called a processed product). In the following description, specific examples of the cutting tool, holder, electric motor, etc. are merely illustrative. These specific examples do not provide a basis for limiting the disclosure in this specification.

[0019] The equipment 10 is equipped with a sensor 11. The sensor 11 observes the physical behavior of the equipment indicating the state of the consumable parts 12 and detects a physical quantity indicating this behavior. The sensor 11 detects a physical quantity that changes as the amount of consumption of the consumable parts 12 increases. The physical quantity detected by the sensor 11 is a physical quantity related to the amount of consumption of the consumable parts 12. The sensor 11 outputs a sensor signal that indicates the detected physical quantity. Thus, the sensor 11 detects a physical quantity that changes in relation to the consumption of the consumable parts 12. The sensor 11 can be installed at any position in the equipment 10. The sensor 11 may be installed near the consumable parts 12. Furthermore, the sensor 11 may be installed in a device separate from the equipment 10.

[0020] The sensor 11 is provided by, for example, a sensor that detects sound, vibration, or temperature. If the sensor 11 is a sound sensor, the sensor 11 detects, for example, a change in sound frequency caused by an increase in the number of uses of the consumable part 12. If the sensor 11 is a vibration sensor, the sensor 11 detects, for example, an increase in vibration amplitude caused by an increase in the number of uses of the consumable part 12. If the sensor 11 is a temperature sensor, the sensor 11 detects, for example, an increase in temperature caused by an increase in the number of uses of the consumable part 12.

[0021] Furthermore, the sensor 11 can detect a physical quantity that indicates an abnormality in the other component 13. In other words, the other component 13 is a component other than the consumable component 12 whose abnormality can be detected by the sensor 11. For example, if there is an abnormality in the illustrated holder, the fixed state of the consumable component 12 cannot be maintained in the normal state, and therefore the abnormality of the holder appears in the physical quantity observed by the sensor 11.

[0022] The system 1 includes a control device 30. The control device 30 includes at least one processor and is configured to provide predetermined functions described below. The control device 30 is provided by a control device including an electrical processing circuit, such as a computer. The control device 30 includes a CPU 31 including a processor core. The control device 30 includes a memory (MMR) 32 that stores a program including multiple instruction codes executed by the CPU 31. The control device 30 includes a hardware circuit (HDW) 33 that executes predetermined processing. The hardware circuit 33 may be provided by an accelerator circuit or an FPGA, which will be described later. The hardware circuit 33 enables real-time processing of at least part of the processing in the control device 30. The hardware circuit 33 may provide a diagnostic processing unit 42, which will be described later.

[0023] The control device in this specification may also be referred to as an Electronic Control Unit (ECU). The control device or control system is provided by (a) an algorithm in the form of multiple logics called an if-then-else format, or (b) an algorithm in the form of a trained model tuned by machine learning, for example, a neural network.

[0024] The control device is provided by a control system including at least one computer. The control system may include multiple computers linked by data communication devices. The computer includes at least one processor that is hardware (a hardware processor). The hardware processor can be provided by (i), (ii), or (iii) below.

[0025] (i) A hardware processor may be at least one processor core that executes a program stored in at least one memory. In this case, a computer is provided with at least one memory and at least one processor core. The processor core is called a CPU (Central Processing Unit), a GPU (Graphics Processing Unit), a RISC-CPU, or the like. A memory is also called a storage medium. A memory is a non-transitory, tangible storage medium that non-temporarily stores "programs and / or data" that can be read by a processor. The storage medium is provided by a semiconductor memory, a magnetic disk, an optical disk, or the like. A program may be distributed independently or as a storage medium on which the program is stored.

[0026] (ii) A hardware processor may be a hardware logic circuit. In this case, the computer is provided by a digital circuit including a large number of programmed logic units (gate circuits). The digital circuit is also called a logic circuit array, for example, ASIC: Application-Specific Integrated Circuit, FPGA: Field Programmable Gate Array, SoC: System on a Chip, PGA: Programmable Gate Array, CPLD: Complex Programmable Logic Device, etc. The digital circuit may include a memory that stores programs and / or data. The computer may be provided by an analog circuit. The computer may be provided by a combination of digital and analog circuits.

[0027] (iii) The hardware processor may be a combination of (i) and (ii) above, where (i) and (ii) are located on different chips or on a common chip. In these cases, part (ii) is also called an accelerator.

[0028] The controller, the signal source and the controlled object provide various elements, at least some of which may be referred to as blocks, modules or sections. Furthermore, the elements included in the control system are referred to as functional means only if this is intentional.

[0029] The control device 30 includes a plurality of processing units. Note that the order of the processing units is merely an example, and the order of the processing units may be changed so as to achieve the intended purpose. The fact that the order of the processing units is an example should be understood in the same manner with respect to subsequent embodiments.

[0030] The control device 30 includes a signal processing unit 41. The signal processing unit 41 receives a sensor signal from the sensor 11. As a result, the control device 30 acquires, from the consumable part 12, a physical quantity that changes in relation to wear.

[0031] The control device 30 includes a diagnostic processing unit 42. The diagnostic processing unit 42 diagnoses the degree of wear of the consumable part 12 based on the sensor signal. The diagnostic processing unit 42 diagnoses the wear state of the consumable part 12 and outputs information indicating the lifespan of the consumable part 12. The diagnostic processing unit 42 is configured to output information including the remaining amount of the consumable part 12 from the sensor signal by implementing a trained model constructed by machine learning. The remaining amount decreases as the consumable part 12 is used. The remaining amount indicates the remaining amount of the consumable part 12 that can be used. The remaining amount may be the remaining number of times that the consumable part 12 can be used for processing, the processing distance that can be processed using the consumable part 12, the remaining time that the consumable part 12 can be used for processing, the remaining number of items that can be processed using the consumable part 12, etc. In this way, the remaining amount is an index suitable for expressing the expiration date of the consumable part 12 for each type of consumable part 12, processing purpose, and processed item.

[0032] The diagnostic processing unit 42 outputs the state of the consumable part 12 for calculating the remaining number of times, which will be described later. The diagnostic processing unit 42 outputs the state of the consumable part 12 for detecting a failure of the consumable part 12. For example, if the sensor signal indicates abnormal behavior of the consumable part 12, this may indicate a failure of the consumable part 12. Furthermore, the diagnostic processing unit 42 outputs the state of the consumable part 12 for detecting a sign of a failure of the consumable part 12. For example, if the sensor signal intermittently indicates abnormal behavior of the consumable part 12, this may indicate a sign of a failure of the consumable part 12.

[0033] The diagnostic processing unit 42 also diagnoses the states of other parts 13 other than the consumable part 12. The diagnosis of the states of other parts 13 is performed incidentally when the fluctuation in the sensor signal does not indicate the behavior of the consumable part 12. When the fluctuation in the sensor signal does not indicate the behavior of the consumable part 12, the diagnostic processing unit 42 consequently diagnoses the other parts 13 for failure or signs of failure.

[0034] The diagnostic processing unit 42 diagnoses the wear state of the consumable parts 12 using machine learning. The results of this diagnosis include (i) normal wear of the consumable parts 12, (ii) failure or signs of failure of the consumable parts 12, and (iii) failure or signs of failure of parts 13 other than the consumable parts 12. In subsequent processing, if the wear is normal, the remaining number of times is calculated. In this embodiment, by comparing the remaining number of times with information on the production plan number, replacement is planned so that the production plan number is met and the replacement of the consumable parts 12 is carried out efficiently. Efficient replacement of the consumable parts 12 is achieved by minimizing the number of replacements.

[0035] The control device 30 includes a remaining number calculation unit 43. The remaining number is one of the replacement support information 60a. The replacement support information 60a is information for supporting the replacement of the consumable part 12. The remaining number also indicates the number of times the consumable part 12 can be used while still functioning normally. As the amount of wear of the consumable part 12 increases, the remaining number decreases. If the consumable part 12 is unused, the remaining number is a standard number set based on the standard quality of the consumable part 12. Unused parts include new parts used for the first time and recycled parts that have been reclaimed for reuse. If the consumable part 12 is used once for one workpiece, the remaining number may be understood as the number of workpieces for which the consumable part 12 can be used normally. The remaining number provides an important indicator for a worker replacing the consumable part 12 to plan a work. Based on the remaining number and the frequency of use of the consumable part 12, it is possible to estimate the desired replacement time in seconds.

[0036] The control device 30 includes a replacement time calculation unit 44. The replacement time is one piece of replacement assistance information 60a. The replacement time calculation unit 44 calculates the time at which the remaining number of uses of the consumable part 12 will reach zero (0), for example, from the remaining number of uses of the consumable part 12 and the frequency of use of the consumable part 12. Alternatively, the replacement time calculation unit 44 calculates the time at which the remaining number of uses will reach an allowable number or less, from the remaining number of uses of the consumable part 12 and the frequency of use of the consumable part 12. The allowable number of uses is an example of an allowable amount. The allowable number of uses is the number of times at which the remaining number of uses of the consumable part 12 can be considered to be zero (0). The replacement time is calculated in units of seconds.

[0037] As a result, the control device 30 generates replacement assistance information including the remaining number of times and the replacement time based on the acquired physical quantities. The remaining number of times is the remaining number of times that the consumable part 12 can be used. The replacement time is the time when replacement of the consumable part 12 is required. The replacement time can sometimes be predicted from the remaining number of times.

[0038] The control device 30 includes a replacement information adjustment unit 45. The replacement information adjustment unit 45 adjusts information to provide replacement assistance information 60a for efficiently replacing consumable parts 12. For example, when multiple consumable parts 12 need to be replaced, the replacement information adjustment unit 45 adjusts the replacement time to enable efficient replacement by performing multiple replacement tasks consecutively. The adjustment of the replacement time is provided by advancing or delaying the replacement time. For example, the replacement information adjustment unit 45 may generate a replacement order based on the remaining number of replacements and adjust the replacement information to include this order. Furthermore, for example, the replacement information adjustment unit 45 may adjust the replacement information based on a production plan described below to enable efficient replacement while achieving the production plan. For example, the replacement information adjustment unit 45 may adjust the replacement time to minimize the time the equipment 10 is stopped for replacement of consumable parts 12.

[0039] The control device 30 includes a display processing unit 46. The display processing unit 46 executes processing for displaying replacement information on a display device 61 (described later). The display processing unit 46 causes the display device 61 to display text information including the remaining number of uses and the replacement time. The display processing unit 46 can set or change the color and size of the displayed text and / or pattern. Furthermore, the display processing unit 46 may output sound in addition to the display function. Furthermore, the display processing unit 46 may change the color or size of the text depending on the urgency of the replacement indicated by the replacement time. As a result, the control device 30 causes the display device 61 to display the replacement assistance information.

[0040] The control device 30 includes a report processing unit 47. The report processing unit 47 generates shared information related to the replacement of the consumable part 12. The shared information is information that is desirable to be provided to entities that make up the supply chain involving the consumable part 12. Furthermore, the report processing unit 47 transmits the shared information to the entities that make up the supply chain.

[0041] This allows multiple business entities that make up the supply chain to participate in improvement activities related to the consumable parts 12 and the replacement of the consumable parts 12. These improvement activities include a variety of improvements, such as improvements to the consumable parts 12 themselves, improvements to the equipment 10 to improve replacement work, and simplification of the process of ordering and receiving the consumable parts 12. In this way, the control device 30 is configured to share information related to the replacement of the consumable parts 12 among the multiple business entities.

[0042] The system 1 includes a server 50. The server 50 provides a storage device that stores predetermined information and provides the requested information in response to a request from the control device 30.

[0043] The server 50 includes a production information storage unit 51. The production information storage unit 51 may store, for example, the planned number of processes to be performed using the consumable parts 12 per day. The planned number of processes may be set based on any unit period, such as daily, weekly, or monthly. The planned number of processes may be set as the planned number of processes to be performed on the workpieces. The production information storage unit 51 may store, for example, frequency information on the processing of the consumable parts 12. The frequency information may be set as the cycle time for the consumable parts 12. The production information storage unit 51 may include process information indicating the order in which the multiple consumable parts 12 are used for the workpieces. The production information storage unit 51 may store information including a production plan indicating the number of processes to be performed on the workpieces. When multiple types of workpieces are targeted, the production information storage unit 51 may store information including a production plan indicating the number of processes to be performed on each type of workpiece.

[0044] The server 50 includes a part information storage unit 52. The part information storage unit 52 stores part information related to the consumable parts 12. The part information may include, for example, information about suppliers that supply the consumable parts 12. The part information may include, for example, quality information indicating the quality of the consumable parts 12. The quality information may include one or more items related to the quality of the consumable parts 12. The quality information may include, for example, dimensional variation, shape variation, flatness variation, and the presence or absence of chipped edges. The quality information may also include material variation, hardness variation, and the like. The part information may include lot information for the consumable parts 12. The lot information indicates the production unit of the consumable parts 12. The lot information may indicate, for example, slight differences in material due to differences in the manufacturing date. The part information storage unit 52 may store part information including type information indicating whether the consumable parts 12 are reusable or disposable.

[0045] The server 50 includes a facility information storage unit 53. The facility information storage unit 53 stores information related to the facility 10. The facility information storage unit 53 may include, for example, information about suppliers that supply the facility 10.

[0046] The system 1 includes an output device 60. The output device 60 outputs information related to the replacement of the consumable part 12. The output device 60 contributes to sharing information among multiple business entities that make up the supply chain.

[0047] The output device 60 includes a display device 61 for displaying replacement assistance information. The display device 61 displays the information to a worker who is responsible for replacing the consumable parts 12. The display device 61 may be provided by a liquid crystal monitor installed together with the control device 30. Alternatively or additionally, the display device 61 may be provided by a tablet monitor that can be carried by the worker.

[0048] The worker is provided with replacement assistance information 60a from the display device 61. Based on the replacement assistance information 60a, the worker can formulate and implement a work plan to reduce the workload. Based on the replacement assistance information 60a, the worker can, for example, replace the consumable parts 12 under the management of the system 1. Based on the replacement assistance information 60a, the worker can, for example, learn the effect of reducing the replacement work of the consumable parts 12. Based on the replacement assistance information 60a, the worker can, for example, plan and implement the ordering of replacement parts for the consumable parts 12.

[0049] The output device 60 includes a communication device 62. The communication device 62 transmits the report generated by the report processing unit 47 to suppliers that make up the supply chain. The suppliers that receive the report are, for example, an equipment supply business entity 63 and a parts supply business entity 64.

[0050] 2 shows a supply chain related to system 1. The diagram illustrates a series of supply chains including a material procurement stage 2, a manufacturing stage 3, a logistics, delivery, and sales stage 4, and an after-sales service stage 5. An equipment supplying entity 63 is a supplier that supplies equipment 10. A parts supplying entity 64 is a supplier that supplies consumable parts 12. Furthermore, the diagram illustrates arrows pointing from the consumable parts 12 to the equipment supplying entity 63 and the parts supplying entity 64. These arrows indicate the flow of reports provided by system 1 to the equipment supplying entity 63 and the parts supplying entity 64 in relation to the replacement of consumable parts 12.

[0051] The report provided to the equipment supply business entity 63 includes information that contributes to the improvement of the equipment 10. The report may include one or more of the following information. The report may include, for example, (i) the usage environment of the consumable part 12. For example, if the consumable part 12 is a cutting tool, the usage environment may include the temperature of the cutting point, the relative speed between the workpiece and the cutting tool, the feed rate of the cutting tool, the amount of cutting oil supplied, etc. The report may include, for example, (ii) a sensor signal at a predetermined time or for a predetermined period before the replacement of the consumable part 12 occurs. The sensor signal may be important information related to the replacement of the consumable part 12. The report may include, for example, (iii) the availability rate of the equipment 10. The report may include, for example, (iv) a history of shutdowns of the equipment 10 due to failures and signs of failure. Based on the report, the equipment supply business entity 63 can consider and implement improvements to the equipment 10 to improve the availability rate of the equipment 10. Based on the report, the equipment supply business entity 63 can consider and implement improvements to the equipment 10 to facilitate recovery operations from shutdowns.

[0052] The report provided to the parts supplying entity 64 includes information that contributes to improving the consumable parts 12. The report may include one or more of the following information: The report may include, for example, (i) the usage environment of the consumable parts 12. If the consumable parts 12 are cutting tools, the usage environment may include, for example, the temperature of the cutting point, the relative speed between the workpiece and the cutting tool, the feed rate of the cutting tool, and the amount of cutting oil supplied. The report may include, for example, (ii) a sensor signal at a predetermined time or for a predetermined period before the replacement of the consumable parts 12 occurs. The sensor signal may be important information related to the replacement of the consumable parts 12. The report may include, for example, (ii) the variation in the quality of the delivered consumable parts 12. The report may include, for example, (iii) a forecast of the order quantity of the consumable parts 12. Based on the report, the parts supplying entity 64 can learn the usage conditions that depend on the quality of the consumable parts 12 and can consider and implement improvements to the quality of the consumable parts 12. The parts supply business entity 64 can plan and implement a production plan for the consumable parts 12 based on the report.

[0053] As a result, the system 1 can provide useful information to suppliers related to the replacement of consumable parts 12 in a supply chain centered around a manufacturing entity.

[0054] 3 is a flowchart showing a program executed by the control device 30. Note that the order of the steps shown in the flowchart is merely an example, and the order of the steps may be changed so as to achieve the intended purpose. The fact that the order of the steps is an example should be understood in the same manner for subsequent embodiments. This flowchart shows the flow of a method implemented in the control device 30. Process 180 is executed continuously over a long period of time while the equipment 10 is in operation. This allows process 180 to accurately determine the lifespan of the consumable part 12.

[0055] In step 181, the control device 30 acquires information necessary for a series of processes. The necessary information includes a sensor signal. The sensor signal is acquired from the sensor 11. The necessary information further includes production information, parts information, and equipment information. The production information, parts information, and equipment information are acquired from the server 50. Step 181 provides the signal processing unit 41.

[0056] In step 182, the control device 30 diagnoses the condition of the consumable part 12 based on the sensor signal. The condition of the consumable part 12 is diagnosed based on the sensor signal. The processing in step 182 is performed by a learned model trained by machine learning. Step 182 provides a diagnosis processing unit 42.

[0057] In step 183, the control device 30 determines whether the diagnosis result in step 182 is normal. The diagnosis in step 182 includes whether the sensor signal is normal or abnormal. If the sensor signal is normal in step 183, the process branches to YES and proceeds to step 184. If the sensor signal is not normal in step 183, the process branches to NO and proceeds to step 185.

[0058] In step 184, the control device 30 determines that the equipment 10 is functioning normally and calculates the remaining number of times of the consumable part 12. Step 184 provides the remaining number calculation unit 43.

[0059] In step 185, the control device 30 determines whether the abnormality in the sensor signal is caused by the consumable part 12. If in step 185 the abnormality in the sensor signal is caused by the consumable part 12, the process branches to YES and proceeds to step 186. If in step 185 the abnormality in the sensor signal is not caused by the consumable part 12, the process branches to NO and proceeds to step 187.

[0060] In step 186, the control device 30 determines that a failure of the consumable part 12 or a symptom of a failure of the consumable part 12 has occurred.

[0061] In step 187, the control device 30 determines that a failure of a part 13 other than the consumable part 12 or a sign of a failure of a part 13 other than the consumable part 12 has occurred.

[0062] If step 186 or step 187 is executed, the control device 30 stops the equipment 10 in step 188. Note that in step 188, the operation of the equipment 10 may be continued without stopping the equipment 10.

[0063] In step 191, the control device 30 determines replacement assistance information 60a including the replacement time. If step 184 has been reached, the time when the remaining number of times of the consumable part 12 will reach zero (0) is predicted based on the cycle time, and the replacement time is determined. If step 186 or step 187 has been reached, the current time is determined as the replacement time to replace the part that caused the abnormality in the sensor signal.

[0064] In step 192, the control device 30 displays the exchange assistance information 60a on the display device 61.

[0065] 4 shows an example of exchange support information 60a. The specific numerical values ​​shown are merely examples for the purpose of aiding understanding and are not intended to provide a basis for limiting the disclosure of this specification. The fact that the numerical values ​​are examples should be understood in the same manner with respect to the preceding and subsequent embodiments.

[0066] The display device 61 displays replacement assistance information 60a. The replacement assistance information 60a includes an equipment ID 65a that identifies the equipment 10 and a part ID 65b that identifies the consumable part 12. The equipment ID 65a and part ID 65b are also referred to as fixed static information 65. The replacement assistance information 60a includes a diagnosis result 66a, a remaining number of times 66b, and a replacement time 66c. The diagnosis result 66a is the diagnosis result for a part diagnosed as abnormal. The diagnosis result 66a, the remaining number of times 66b, and the replacement time 66c are also referred to as dynamic information 66 that can change dynamically.

[0067] The replacement support information 60a includes basis information 67 for calculating the dynamic information 66. The basis information 67 includes, for example, a maximum capacity 67a, a standard life 67b, and a usage plan 67c. The maximum capacity 67a is also called a cycle time.

[0068] 3, the control device 30 determines whether or not it is time to send a report in step 193. The sending time is set, for example, at regular intervals.

[0069] The control device 30 transmits the report in step 194. The report is transmitted to the equipment supply business entity 63 and / or the parts supply business entity 64.

[0070] According to this embodiment, workers are not only required to replace parts. The workers tasked with replacing parts are informed of the remaining number of uses of the consumable parts 12. This allows the workers to plan the replacement work, reducing the burden on the workers. The manufacturing entity can reduce the number of man-hours required for replacing the consumable parts 12 and predict the number of consumable parts 12 to be ordered.

[0071] According to this embodiment, information related to consumable parts and their replacement can be provided to suppliers in the supply chain through reports. For example, a business entity that supplies equipment can be notified of data indicating the availability rate of the equipment 10 and / or a history of shutdowns of the equipment 10 due to failures (including signs of failure). A business entity that supplies parts can be notified of variations in the quality of the consumable parts 12 and the predicted number of consumable parts 12 to be ordered.

[0072] As a result, it is possible to encourage suppliers to improve their parts and / or equipment. For example, the equipment supply entity can identify areas of the equipment 10 that need improvement and plan and implement specific improvement measures. For example, the parts supply entity can provide advice to the manufacturing entity regarding the handling of consumable parts 12 and plan and implement improvements to the consumable parts 12.

[0073] Second Embodiment This embodiment is a modification of the preceding embodiment. In the preceding embodiment, the consumable part 12 was a single part. Instead, in this embodiment, the equipment 10 includes multiple consumable parts 212a, 212b, and 212n. Note that, although the illustrated example shows three consumable parts, this is merely an example and the number of consumable parts may be two, four, or more.

[0074] 5, the equipment 10 includes a plurality of consumable parts 212a, 212b, and 212n. In this embodiment, replacement assistance information 60a is generated and output for each of the plurality of consumable parts 212a, 212b, and 212n.

[0075] 6 shows replacement assistance information 260a displayed on a display device 61. In this embodiment, the replacement assistance information 60a also includes static information 65, dynamic information 66, and evidence information 67. In this embodiment, the replacement assistance information 60a also includes replacement order information 266d for the multiple consumable parts 212a, 212b, and 212n.

[0076] In the illustrated example, a fault has occurred in consumable part 212a. Therefore, the remaining number of times for consumable part 212a is zero (0). Furthermore, the replacement time is the present. In other words, the replacement time indicates immediate replacement. Consumable part 212b is normal and the remaining number of times is 150. The replacement time for consumable part 212b is specified in seconds. Consumable part 212n has a remaining number of times of 1200, which is sufficiently large compared to the planned number of usages Nn. In the illustrated example, the replacement order is set as follows: consumable part 212a is first, consumable part 212b is second, and consumable part 212n is third.

[0077] According to this embodiment, the worker is not only required to replace parts, but also can plan and coordinate the replacement work of multiple consumable parts 12, thereby reducing the burden on the worker.

[0078] Third Embodiment This embodiment is a modification of the preceding embodiment. In the above embodiment, the facility 10 to be managed is a single facility. Instead, in this embodiment, the facility 10 includes multiple facilities 310a, 310b, and 310n. In the illustrated example, the number of facilities 10 is three, but this is merely an example, and the number may be two, four, or more.

[0079] 7, the equipment 10 includes a plurality of pieces of equipment 310a, 310b, and 310n. In this embodiment, replacement assistance information 60a is generated and output for each of the consumable parts 312a, 312b, and 312n of the plurality of pieces of equipment 310a, 310b, and 310n.

[0080] 8 shows replacement assistance information 360a displayed on the display device 61. In this embodiment, the replacement assistance information 60a also includes static information 65, dynamic information 66, and evidence information 67. In this embodiment, the replacement assistance information 60a also includes replacement order information 266d for the multiple consumable parts 312a, 312b, and 312n.

[0081] In this embodiment, the worker is not only required to replace parts, but also can plan and coordinate the replacement work of multiple consumable parts 12, thereby reducing the burden on the worker.

[0082] Fourth Embodiment This embodiment is a modification based on the preceding embodiment. In the above embodiment, the system 1 is constructed within a geographically limited area. For example, the system 1 is constructed within a single factory. Alternatively, in this embodiment, the system 1 includes multiple systems 401a, 401b, and 401n that are geographically separated from one another. The multiple systems 401a, 401b, and 401n may be constructed in multiple geographically separated factories. Here, "geographically separated from one another" refers to multiple systems located in different factories, multiple systems located in different administrative districts, and / or multiple systems located in different countries. Note that in the illustrated example, the number of systems 1 is three, but this is merely an example and the number may be two, four, or more.

[0083] As shown in FIG. 9 , multiple systems 401a, 401b, and 401n are connected to one another via an electrical communication network NW. The multiple systems 401a, 401b, and 401n constitute a single integrated system. System 401a can display and transmit consumable part replacement support information 60a for the equipment 10 belonging to itself as well as the equipment 10 belonging to the other systems 401b and 401n. In this embodiment, multiple production bases, both domestic and overseas, are connected via a network. Furthermore, the consumable part replacement support information 60a can be shared and viewed by each other.

[0084] This embodiment exposes differences in equipment and / or parts among the multiple systems 401a, 401b, and 401n. In other words, differences in equipment and / or parts among the multiple systems 401a, 401b, and 401n are visualized. Even with the same equipment or the same consumable parts, differences in the replacement times of the consumable parts can be expected due to, for example, the following differences: (i) the consumable parts are not supplied by the same supplier; (ii) there are differences in the maintenance periods for the equipment; (iii) there are geographical climate differences, resulting in different environments in which the equipment is installed; and (iv) there are differences in the skill levels of the workers.

[0085] According to this embodiment, it is possible to manage consumable parts in multiple systems. More specifically, it is possible to centrally manage parts at multiple locations. From another perspective, it is possible to manage the overall production volume across multiple locations. From another perspective, it is possible to identify problems specific to a specific location among the multiple locations.

[0086] Fifth Embodiment This embodiment is a modification of the preceding embodiment. In the preceding embodiment, the quality of the consumable parts 12 is not included in the management target. Instead, in this embodiment, the quality of the consumable parts 12 is reflected in the replacement support information 60a.

[0087] 10 , process 580 includes step 589 after step 184 and step 188. Step 589 is arranged before step 191. In step 589, the control device 30 determines a replacement plan according to the quality of the consumable parts 12. The replacement plan is adjusted to improve the efficiency of the replacement work according to the quality of the consumable parts 12. The replacement plan determined in step 589 is reflected in the replacement assistance information 60a in the subsequent step 191. Furthermore, the replacement plan determined in step 589 is reflected in the display on the display device 61 in the subsequent step 192. As a result, the worker can perform efficient replacement work according to the quality of the consumable parts 12.

[0088] 11 shows a flowchart for obtaining and registering the quality of the consumable part 12. Process 571 identifies the quality of the consumable part 12 and additionally registers the quality information as part of the part information. In this embodiment, the quality of the consumable part 12 is registered in advance before use of the consumable part 12 begins. The quality of the consumable part 12 can be identified by conducting an acceptance inspection when the part is received at a factory where the system 1 is operating. Alternatively or in addition to this, the quality of the consumable part 12 may be identified by an application from the part supplying entity.

[0089] In step 572, the control device 30 identifies the quality of the consumable part 12. The quality can be obtained by inspecting the part. For example, the quality can be identified for each production lot of delivered parts. Various quality factors can be used for the quality, such as material and sharpness.

[0090] In step 573, the control device 30 adds the quality of the consumable part 12 to the part information stored in the part information storage unit 52. This allows the control device 30 to acquire the quality information of the consumable part 12 from the part information storage unit 52.

[0091] In this embodiment, for example, the following processing is realized. Here, it is assumed that product Pa is processed in parallel by multiple pieces of equipment 10a and 10b. It is assumed that there is a difference in production capacity between the pieces of equipment. The production capacity of equipment 10a is higher than the production capacity of equipment 10b. It is also assumed that the consumption of consumable parts 12 in equipment 10a is faster than the consumption of consumable parts 12 in equipment 10b. It is assumed that the quality of consumable parts 12 is managed for each lot and stored in the part information storage unit 52.

[0092] In one example, in step 589, the control device 30 determines a replacement plan as follows: (i) A replacement part from a relatively high-quality lot is used to replace the consumable parts 12 of the equipment 10a. (ii) A replacement part from a relatively low-quality lot is used to replace the consumable parts 12 of the equipment 10b. Determining such a replacement plan is effective in suppressing the difference in replacement time.

[0093] In another example, in step 589, the control device 30 determines a replacement plan as follows: (i) A replacement part from a relatively low-quality lot is used to replace the consumable parts 12 in the facility 10a. (ii) A replacement part from a relatively high-quality lot is used in the facility 10b. Determining such a replacement plan is effective in reducing the number of replacements in the facility 10b.

[0094] Furthermore, in this embodiment, for example, the following process is realized. Here, it is assumed that product Pa is processed in parallel by multiple pieces of equipment 10a and 10b. It is assumed that equipment 10b is more deteriorated than equipment 10a. It is assumed that the processing yield of the product in equipment 10b is lower than the processing yield of the product in equipment 10a.

[0095] In one example, in step 589, the control device 30 determines a replacement plan as follows: (i) A relatively high-quality consumable part 12 is used to replace the consumable part 12 of the equipment 10a. (ii) A relatively low-quality consumable part 12 is used to replace the consumable part 12 of the equipment 10b. Such a replacement plan is effective in suppressing a decrease in the processing yield of the equipment 10a.

[0096] In another example, in step 589, the control device 30 determines a replacement plan as follows: (i) A relatively low-quality consumable part 12 is used to replace the consumable part 12 of the equipment 10a. (ii) A relatively high-quality consumable part 12 is used to replace the consumable part 12 of the equipment 10b. Such a replacement plan is effective in improving the processing yield of the equipment 10b.

[0097] In this embodiment, the control device 30 is configured to determine a replacement plan based on the quality information stored in the part information storage unit 52. The control device 30 is configured to generate and output replacement assistance information including the replacement plan. The replacement plan is planned to replace one consumable part 12 with a consumable part 12 of relatively high quality. The replacement plan is planned to replace another consumable part 12 with a consumable part 12 of relatively low quality. The replacement assistance information specifies, for each replacement time, an old consumable part 12 whose usage count has reached its upper limit and a new consumable part 12 of selected quality.

[0098] According to this embodiment, performance according to the quality of the new consumable parts 12 can be obtained in the equipment 10. When replacement is performed in one equipment 10, consumable parts 12 of the intended quality are used, so that the intended performance can be obtained. When replacement is performed in multiple equipment 10, the difference in performance among the different equipment can be utilized to obtain overall superior performance.

[0099] Sixth Embodiment This embodiment is a modification of the preceding embodiment. In the preceding embodiment, the production process is not included in the management target. Instead, in this embodiment, the position of the consumable part 12 in the production process is reflected in the replacement support information 60a.

[0100] As shown in FIG. 12 , process 680 includes step 689 instead of step 589. In step 689, the control device 30 determines a replacement plan for efficient replacement of consumable parts 12 based on process information in the equipment 10. The control device 30 acquires the process information from the production information storage unit 51. The control device 30 is configured to adjust the remaining number of times and the replacement time based on the process information. The process information is indicated, for example, by the use order of the consumable parts 12. The replacement plan is adjusted based on the process information to improve the efficiency of the replacement work. When multiple consumable parts 12 are suspected to be abnormal, the control device 30 adjusts the remaining number of times and the replacement time based on the process information so that the consumable parts 12 with a high probability of abnormality are replaced first. For example, the control device 30 adjusts the remaining number of times of the consumable parts 12 with a high probability of abnormality to zero (0) and adjusts the replacement time to the current time.

[0101] The replacement plan determined in step 689 is reflected in the replacement assistance information 60a in the subsequent step 191. Furthermore, the replacement plan determined in step 689 is reflected in the display on the display device 61 in the subsequent step 192.

[0102] 13 shows a process chart 675 indicating the production process of the facility 10. Furthermore, the figure shows a display example of exchange support information 60b in a comparative example and a display example of exchange support information 660a in this embodiment. Note that the exchange support information 60b in the comparative example is similar to the exchange support information 260a, 360a in the second or third embodiment.

[0103] It is assumed that the production process includes the steps described below. Product Pa has a workpiece WK. In this embodiment, multiple consumable parts Ta, Tb, and Tc are used. The multiple consumable parts are used in sequence for one workpiece WK. Normal and abnormal shapes of the workpiece WK are assumed. In the normal case, the workpiece WK is machined in the order described below. The production process includes a step P(a) in which the workpiece WK is machined by equipment Fa. In the step P(a), a shape Sa is machined. After the step P(a), the production process includes a step P(b) in which the workpiece WK is machined by equipment Fb. In the step P(b), a shape Sb is machined. After the step P(b), the production process includes a step P(c) in which the workpiece WK is machined by equipment Fc. In the step P(c), a shape Sc is machined. It is assumed that the machining accuracy in steps P(a), P(b), and P(c) increases stepwise.

[0104] In an abnormal case, the workpiece WK is machined in the following order: When an abnormality occurs in the equipment Fa, an abnormal shape IRs is machined into the part WK. Due to the abnormal shape IRs, an abnormal shape is also machined in the equipment Fb. Due to the abnormal shape IRs, an abnormal shape is also machined in the equipment Fc.

[0105] In such a production process, it is assumed that only equipment Fa has an actual abnormality (marked with an X). The abnormal shape IRs causes the shape of the workpiece WK to become abnormal. On the other hand, equipment Fb and Fc are actually normal (marked with an O). However, in all processes, abnormalities are detected by the sensor 11 due to the abnormal shape IRs. Therefore, the result of the diagnosis process in step 182 is that all processes are determined to be abnormal (marked with an X).

[0106] In this case, in the comparative example, all of the consumable parts Ta, Tb, and Tc are determined to be faulty. As a result, the replacement time is set to the current time and displayed. When an operator sees this replacement assistance information 60b, they are prompted to immediately replace the consumable parts at the current time.

[0107] In contrast, in this embodiment, the processing steps included in the production information are obtained from the production information storage unit 51. Furthermore, in step 689, the control device 30 determines that only the consumable part Ta of the equipment Fa is faulty, reflecting the processing order of the equipment. As a result, the consumable part Tb of the equipment Fb and the consumable part Tc of the equipment Fc are not determined to be faulty.

[0108] In this way, according to this embodiment, the replacement plan is determined by reflecting the production process, thereby reducing the number of replacements of the consumable parts 12. Note that, although this embodiment has been described as an example in which three pieces of equipment perform processing in sequence, the present invention is not limited to this example. The production process may also assume a case in which multiple consumable parts 12 are processed in sequence in one piece of equipment.

[0109] Seventh Embodiment This embodiment is a modification of the preceding embodiment. In the preceding embodiment, the production plan is not included in the management target. Instead, in this embodiment, the replacement of consumable parts 12 is reflected in the replacement support information 60a so as to reduce the impact of the replacement of consumable parts 12 on the production plan.

[0110] 14 , process 780 includes step 789 instead of step 689. In step 789, the control device 30 determines a replacement plan for efficient replacement of the consumable parts 12 based on the production plan for the facility 10. The production plan is indicated, for example, by the planned production volume of products to be produced by the facility 10. The replacement plan is determined, for example, so as to reduce the number of stoppages of the facility 10 while achieving the planned production volume.

[0111] 15 shows a planning table 775 indicating the production plan 400 / day and the remaining number of times for product Pa. Furthermore, the same figure shows a display example of replacement support information 60b in a comparative example and a display example of replacement support information 760a in this embodiment.

[0112] Here, it is assumed that the planned daily production volume of product Pa is 400 units. It is assumed that the cycle time of product Pa is 72 seconds. It is assumed that the processing capacities of facilities Fa, Fb, and Fc are equal, and the hourly production volume is 50 units. Therefore, in this embodiment, the consumable part is one of multiple consumable parts Ta, Tb, and Tc that can be selectively used for one workpiece. The multiple consumable parts Ta, Tb, and Tc can be used alternatively for one workpiece. The multiple consumable parts Ta, Tb, and Tc can be selectively used for one workpiece.

[0113] In the comparative example, all three pieces of equipment Fa, Fb, and Fc are in operation. In this case, the replacement assistance information 60a displayed on the display device 61 includes, at 8:00, the replacement time of consumable part Ta of equipment Fa, 11:00:00, and the replacement time of consumable part Tb of equipment Fb, 10:00:00. In other words, in the comparative example, the worker is instructed to perform two replacements.

[0114] On the other hand, in this embodiment, which goes through step 789, the production plan is adjusted to reduce the number of replacements while satisfying the production plan, and replacement support information 760a is determined. In the illustrated example, the replacement times for consumable parts Tb and Ta are adjusted. In step 789, the control device 30 adjusts the production plan to extend the operating time of equipment Fc, which has a relatively large number of remaining replacements, so as to avoid the replacement work of consumable parts Tb and Ta. In other words, the production plan is adjusted to postpone the replacement time. That is, the control device 30 is configured to adjust the distribution of workpieces to multiple consumable parts. This distribution is adjusted so that the production plan stored in the production information storage unit 51 is satisfied and the replacement times of the multiple consumable parts are close to each other. It is desirable that the replacement times of the multiple consumable parts be adjusted to be equal to each other.

[0115] For example, if the production plan of 400 / day can be met with only equipment Fc, the production plan is adjusted to operate only equipment Fc. The production plan is adjusted to minimize the number of replacements. For example, the production plan can be adjusted so that the replacement times of at least two pieces of equipment are close together. In this embodiment, in order to increase the efficiency of the replacement work, the production plan can be adjusted so that the replacement times of at least two pieces of equipment arrive simultaneously.

[0116] In the illustrated example, after the production plan is adjusted, the remaining number of times for equipment Fb remains at 100, the remaining number of times for equipment Fa remains at 150, and only the remaining number of times for equipment Fc decreases from 1,200. In other words, the distribution of the number of production loads for each piece of equipment is intentionally increased. In other words, the replacement time of consumable parts 12 that are diagnosed based on the state of the consumable parts 12 and whose predicted replacement time arrives relatively early can be postponed. In other words, the replacement time of consumable parts 12 that are diagnosed based on the state of the consumable parts 12 and whose predicted replacement time arrives relatively late can be brought forward.

[0117] According to this embodiment, it is possible to reduce the number of times that the multiple consumable parts 12 are replaced while satisfying the production plan, and to carry out the replacement work efficiently.

[0118] Eighth Embodiment This embodiment is a modification of the preceding embodiment. In the preceding embodiment, the production plan for one product is adjusted. Instead, in this embodiment, the production plans for multiple products are adjusted.

[0119] 16 , process 880 includes step 889 instead of step 789. In step 889, the control device 30 determines a replacement plan for efficient replacement of the consumable parts 12 based on the production plan for the facility 10. The production plan is indicated, for example, by the planned production volume of products to be produced by the facility 10. The replacement plan is determined, for example, so as to suppress stoppages of the facility 10 while achieving the planned production volume.

[0120] 17 shows a schedule 875 indicating a production schedule of 1000 / day for product Pa, a production schedule of 200 / day for product Pb, and the remaining number of times for a plurality of pieces of equipment Fa, Fb, Fc, and Fd. Furthermore, the same figure shows a display example of replacement support information 60b in a comparative example and a display example of replacement support information 860a in this embodiment.

[0121] Here, it is assumed that the planned daily production volume of product Pa is 1,000 units, and the planned daily production volume of product Pb is 200 units. It is assumed that the processing capacities of facilities Fa, Fb, Fc, and Fd are equal, with 50 units processed in one hour and 100 units processed in two hours.

[0122] In the comparative example, all four pieces of equipment Fa, Fb, Fc, and Fd are operating. In this case, the replacement assistance information 60b displayed on the display device 61 at 10:00 includes the replacement time of consumable part Td of equipment Fd (12:00:00), the replacement time of consumable part Tb of equipment Fb (16:00:00), the replacement time of consumable part Ta of equipment Fa (hh:mm:ss tomorrow), and the replacement time of consumable part Tc of equipment Fc (hh:mm:ss tomorrow). The order of replacement requests is Td, Tb, Ta, and Tc. In other words, in the comparative example, the worker is instructed to perform two replacements today.

[0123] On the other hand, in this embodiment, which involves step 889, the replacement plan is adjusted to reduce the number of replacements while satisfying the production plan, and replacement support information 860a is determined. In step 889, the control device 30 adjusts the postponement of the replacement time of consumable part Td to 12:00:00. In the illustrated example, the production plan for product Pb can be achieved by restarting equipment Fd and using consumable part Td after the replacement time of consumable part Tb, 16:00:00. That is, in step 889, the control device 30 can determine that the production plan for product Pb can be achieved even if the replacement time of consumable part Td is postponed. In step 889, the control device 30 adjusts the replacement time set based on the condition diagnosis of consumable part 12 to be postponed. As a result, the operator can know that it is possible to stop equipment Fd and equipment Fb at the replacement time of 16:00:00 and perform the replacement work of consumable parts Td and Tb of both equipment consecutively.

[0124] In this embodiment, the consumable part 12 is one of a plurality of consumable parts 12, the number of which corresponds to a plurality of types of workpieces. The control device 30 is configured to adjust the replacement time. The control device 30 adjusts the replacement time so that the production plan stored in the production information storage unit 51 is satisfied and the replacement times of the plurality of consumable parts are close to each other. According to this embodiment, it is possible to reduce the number of replacements of the consumable parts 12 in the equipment while satisfying the production plan, and to perform replacement work efficiently.

[0125] Ninth Embodiment This embodiment is a modification of the preceding embodiment. In the preceding embodiment, the time when the remaining number of times reaches zero (0) is set as the replacement time. Instead, in this embodiment, the time when the remaining number of times reaches or exceeds the allowable number of times is set as the replacement time.

[0126] 18, process 980 includes step 989 instead of step 889. In step 989, the control device 30 determines a replacement plan that will allow efficient replacement work based on the allowable number of times.

[0127] The allowable number of times can be a number according to the characteristics of the consumable part 12. The allowable number of times can be a number that is set in advance in the system 1. Furthermore, the allowable number of times can be set by a feedback method based on the actual remaining number of times that the consumable part 12 has been replaced.

[0128] The allowable number of times can be set taking into consideration the replacement cost of the consumable part 12, etc. The allowable number of times can be set depending on the balance between the cost of the consumable part 12 and the cost of replacement. The cost of replacement can include the cost of calling a worker and / or the cost of work during the replacement work. In the illustrated example, the allowable number of times is assumed to be 30.

[0129] 19 shows a planning table 975 indicating the production plan 1000 / day for product Pa and the remaining number of times for consumable parts in the equipment. Furthermore, the same figure shows a display example of replacement support information 60b in a comparative example and a display example of replacement support information 960a in this embodiment.

[0130] In the comparative example, at 10:00, two replacement times are displayed. The first is the replacement time of 11:00:00, when the remaining number of times for consumable part Td in equipment Fd reaches zero (0). The second is the replacement time of 11:30:00, when the remaining number of times for consumable part Tb in equipment Fb reaches zero (0). Therefore, in the comparative example, the worker is required to know both the replacement time of 11:00:00 and the replacement time of 11:30:00. However, it is difficult to say that performing replacement work on two different pieces of equipment within 30 minutes is efficient.

[0131] On the other hand, in this embodiment, which goes through step 989, the allowable number of times is set. When the remaining number of times for one consumable part reaches zero (0), if the remaining number of times for other consumable parts is less than the allowable number of times, a common replacement time is set. In the illustrated example, at the replacement time of consumable part Td, 11:00, the remaining number of times for consumable part Tb is less than the allowable number of times (25 < 30), so consumable parts Td and Tb can be replaced consecutively at the same time. In the illustrated example, if the remaining number of times for multiple consumable parts Tb and Td are both less than the allowable number of times, a common replacement time of 11:00:00 is set for the multiple consumable parts Tb and Td. This allows the worker to replace consumable parts Tb and Td consecutively. If replacement of a consumable part 12 is permitted when the remaining number of times is less than the allowable number of times, the replacement time is set so that multiple consumable parts 12 can be replaced consecutively. For example, an earlier replacement time among a plurality of replacement times is set as an acceptable common replacement time.

[0132] In this embodiment, the consumable part 12 is one of a plurality of consumable parts Ta, Tb, Tc, and Td. The control device 30 is configured to set the same replacement time as the other consumable parts for a consumable part whose remaining number of uses has fallen below a predetermined allowable number of uses. In the illustrated example, at 11:00, the consumable part Tb whose remaining number of uses (25) has fallen below the predetermined allowable number of uses (30) is set to the same replacement time as the other consumable parts Td, 11:00:00. This allows the worker to perform the replacement work of the consumable part Tb and the replacement work of the consumable part Td consecutively.

[0133] Tenth Embodiment This embodiment is a modification of the preceding embodiment. In the above embodiment, when the remaining number of uses of one consumable part reaches zero (0), and the remaining number of uses of other consumable parts is less than the allowable number of uses, a common replacement time is set. This allowable number of uses can also be applied when a failure (or a symptom of failure) occurs in one consumable part.

[0134] 20 shows a planning table A75 indicating the production plan 1000 / day and the remaining number of times for product Pa. The figure also shows a display example of replacement support information 60b in a comparative example and a display example of replacement support information A60a in this embodiment. Here, it is assumed that a failure occurs in consumable part Tc of equipment Fc at time 10:30.

[0135] In the comparative example, at 10:30, the current time is displayed as the replacement time for consumable part Tc. Therefore, the worker is required to perform the replacement immediately. Subsequently, replacement of consumable part Td of equipment Fd is required at replacement time 11:00:00. Therefore, in the comparative example, the worker is required to replace consumable part Tc of equipment Fc and consumable part Td of equipment Fd within a period of just 30 minutes. However, performing replacement work on two different pieces of equipment within 30 minutes is hardly efficient.

[0136] On the other hand, in this embodiment, which goes through step 989, an allowable number of times is set. When a failure (or a symptom of a failure) occurs in one consumable part, if the remaining number of times of the other consumable parts is less than the allowable number of times, a common replacement time is set. When the remaining number of times of the consumable part 12 is less than the allowable number of times, the consumable part 12 can be replaced.

[0137] In this embodiment, the consumable part 12 is one of a plurality of consumable parts Ta, Tb, Tc, and Td. The control device 30 is configured to set the same replacement time as the other consumable parts for a consumable part whose remaining number of uses has fallen below a predetermined allowable number of uses. In the illustrated example, at 10:30, the remaining number of uses (25) of one consumable part Td has fallen below the predetermined allowable number of uses (30), and the same replacement time as the other consumable parts Tc, 10:30:00, is set for this consumable part. This allows the worker to perform the replacement work of consumable part Tc and the replacement work of consumable part Td consecutively.

[0138] Eleventh Embodiment This embodiment is a modification of the preceding embodiment as a basic form. In the above embodiment, the consumable parts 12 are replaced when the remaining number of uses reaches zero (0), completing their life as consumable parts 12. Consumable parts 12 that have reached the end of their life are discarded or reused as materials. Such consumable parts 12 are called disposable consumable parts. On the other hand, consumable parts 12 include consumable parts that are reused when the remaining number of uses reaches zero (0) or when the remaining number of uses becomes smaller than the allowable number of uses. Such consumable parts 12 are called reusable consumable parts. In this embodiment, the remaining number of uses of disposable consumable parts and the remaining number of uses of reusable consumable parts are set.

[0139] 21, process B80 includes step B84 instead of step 184. In step B84, the control device 30 calculates the remaining number of times depending on whether the consumable part 12 is a disposable type or a reusable type.

[0140] Figure 22 is a graph showing the relationship between the number of times the consumable part 12 can be used and its state of wear. The horizontal axis represents the number of uses Nu. The vertical axis represents the amount of wear Acon, which corresponds to the state of wear. In the graph, in the early stages of use of the consumable part 12, the amount of wear Acon increases rapidly. Thereafter, the amount of wear Acon increases gradually in proportion to the increase in the number of uses Nu. Eventually, towards the end of the use of the consumable part 12, the amount of wear Acon increases rapidly as the number of uses Nu increases.

[0141] Reusable consumable parts 12 achieve a longer overall lifespan as a part through reuse. However, the number of times that reusable consumable parts 12 can be reused is limited. Considering a cutting tool as an example of a consumable part 12, the cutting tool is regenerated into a reusable state through a regeneration process that includes a regrinding process. Furthermore, the amount of regrinding is limited to increase the number of times that the tool can be reused. For these reasons, the number of times that reusable consumable parts 12 can be used in one usage cycle (RUth) is relatively small. On the other hand, disposable consumable parts 12 do not need to be reused, so the number of times that they can be used (OTth) is relatively large. Generally, the number of times that they can be used (RUth) is smaller than the number of times that they can be used (OTth). The number of times that they can be used (RUth, OTth) provide the initial number of times that they can be used for calculating the remaining number of times that the consumable part 12 can be used.

[0142] 21, in step B84, if the consumable part 12 is a reusable type, the remaining number of times from the maximum usable number of times RUth is calculated. In step B84, if the consumable part 12 is a disposable type, the remaining number of times from the maximum usable number of times OTth is calculated.

[0143] 23 is a flowchart showing the details of step B84. In step B84a, the control device 30 acquires identification information for distinguishing between reusable and disposable consumable parts from the part information storage unit 52. The identification information includes information indicating whether the consumable parts 12 used in the equipment 10 are reusable or disposable.

[0144] In step B84b, the control device 30 determines whether the consumable part 12 determined to be normal in step B183 is a reusable type. If the consumable part 12 is a reusable type, the process branches to YES and proceeds to step B84c. If the consumable part 12 is not a reusable type, the process branches to NO and proceeds to step B84d. In other words, if the consumable part 12 is a disposable type, the process branches to NO and proceeds to step B84d.

[0145] In step B84c, the control device 30 calculates the remaining number of times of the reusable consumable part 12. In step B84c, the control device 30 calculates the remaining number of times of the consumable part 12, assuming that the consumable part 12 will be used from the number of uses RUth at which it can be reused.

[0146] In step B84d, the control device 30 calculates the remaining number of uses of the disposable consumable part 12. In step B84d, the control device 30 calculates the remaining number of uses of the disposable consumable part 12, assuming that the consumable part 12 will be used from the number of uses OTth at which it can be used as a disposable consumable part.

[0147] In this embodiment, the control device 30 is configured to generate different remaining numbers of times for a reusable consumable part and for a disposable consumable part, based on the type information stored in the part information storage unit 52. Appropriate replacement assistance information can be provided for a reusable consumable part 12 and a disposable consumable part 12. The replacement assistance information includes remaining numbers of times for a reusable consumable part and for a disposable consumable part. This allows the worker to efficiently replace parts depending on whether the consumable part is reusable or disposable.

[0148] Other Embodiments The disclosure in this specification and drawings, etc. is not limited to the exemplified embodiments. The disclosure encompasses the exemplified embodiments and variations thereon by those skilled in the art. For example, the disclosure is not limited to the combinations of parts and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure encompasses the omission of parts and / or elements from the embodiments. The disclosure encompasses the substitution or combination of parts and / or elements between one embodiment and another embodiment. The disclosed technical scope is not limited to the description of the embodiments. Some disclosed technical scopes are defined by the claims, and should be interpreted as including all modifications within the meaning and scope equivalent to the claims.

[0149] The disclosure in the specification, drawings, etc. is not limited by the claims. The disclosure in the specification, drawings, etc. encompasses the technical ideas described in the claims, and extends to more diverse and broader technical ideas than the technical ideas described in the claims. Therefore, various technical ideas can be extracted from the disclosure in the specification, drawings, etc. without being bound by the claims.

[0150] For example, the above-described embodiments each have different features. These different features can be combined with each other. For example, the ninth embodiment and the tenth embodiment, which set the allowable number of times, can be additionally applied to all other embodiments.

[0151] (Disclosure of Technical Ideas) This specification discloses multiple technical ideas described in the following multiple clauses. Some clauses may be described in a multiple dependent form, with the subsequent clause alternatively referring to the preceding clause. Furthermore, some clauses may be described in a multiple dependent form, with the subsequent clause referring to another multiple dependent clause. These multiple dependent clauses define multiple technical ideas.

[0152] (Technical Idea 1) A system comprising: a consumable part (12) that is a part installed in equipment and that wears out; a sensor (11) that detects a physical quantity that changes in relation to the wear of the consumable part; a control device (30) that includes at least one processor, the processor being configured to generate replacement assistance information (60a, 260a, 360a, 660a, 760a, 860a, 960a, A60a) that includes the remaining amount of the consumable part and the replacement time when the replacement of the consumable part is required based on the physical quantity detected by the sensor; and a display device (61) that displays the replacement assistance information.

[0153] (Technical Idea 2) The consumable parts are parts installed in equipment that processes workpieces, and are consumable parts that wear out according to the number of times the workpieces are processed, and the remaining amount is the remaining number of times the consumable parts can be used on the workpieces, in the system described in Technical Idea 1.

[0154] (Technical Idea 3) The system according to Technical Idea 1 or Technical Idea 2 further comprises a part information storage unit (52) for storing part information including quality information indicating the quality of the consumable parts, and the control device is configured to determine a replacement plan based on the quality information stored in the part information storage unit so as to replace one consumable part with a consumable part of relatively high quality and replace other consumable parts with consumable parts of relatively low quality.

[0155] (Technical Idea 4) A system according to any one of Technical Ideas 1 to 3, further comprising: the consumable part is one of a plurality of consumable parts that are used in sequence for one workpiece; a production information storage unit (51) that stores production information including process information that indicates the order of use of the plurality of consumable parts; and the control device is configured to adjust the remaining amount and the replacement time based on the process information.

[0156] (Technical Idea 5) A system according to any one of Technical Ideas 1 to 3, further comprising a production information storage unit (51) for storing information including a production plan indicating the number of processed workpieces, wherein the consumable part is one of a plurality of consumable parts that can be selectively used for one workpiece, and wherein the control device is configured to adjust the distribution of workpieces to the plurality of consumable parts so that the production plan stored in the production information storage unit is satisfied and the replacement times of the plurality of consumable parts are close to each other.

[0157] (Technical Idea 6) A system according to any one of Technical Ideas 1 to 5, further comprising a production information storage unit (51) for storing information including a production plan indicating the number of processes for each of multiple types of workpieces, wherein the consumable part is one of multiple consumable parts in a number corresponding to the multiple types, and wherein the control device is configured to satisfy the production plan stored in the production information storage unit and adjust the replacement times of the multiple consumable parts so that the replacement times are close to each other.

[0158] (Technical Idea 7) A system described in any one of Technical Ideas 1 to 6, wherein the consumable part is one of a plurality of consumable parts, and the control device is configured to set the same replacement time for one consumable part whose remaining amount has become smaller than a predetermined allowable amount as for the other consumable parts.

[0159] (Technical Idea 8) A system according to any one of Technical Ideas 1 to 7, further comprising a part information storage unit (52) for storing part information including type information indicating whether the consumable part is reusable or disposable, and the control device is configured to generate different remaining amounts when the consumable part is the reusable type and when the consumable part is the disposable type based on the type information stored in the part information storage unit.

[0160] (Technical Idea 9) The system according to any one of Technical Ideas 1 to 8 further comprises an output device for sharing information among a plurality of business entities that make up a supply chain, and the control device is configured to share information related to the replacement of the consumable parts among the plurality of business entities.

[0161] (Technical Idea 10) A method of parts management executed by a control device (30) including at least one processor, comprising: acquiring a physical quantity that changes in relation to wear from a consumable part (12) that is worn out; generating replacement assistance information (60a, 260a, 360a, 660a, 760a, 860a, 960a, A60a) including a remaining amount of the consumable part and a replacement time when the consumable part should be replaced based on the physical quantity; and displaying the replacement assistance information on a display device (61).

[0162] (Technical Idea 11) A program that causes a control device (30) including at least one processor to execute the following operations: acquiring a physical quantity that changes in relation to consumption from a consumable part (12) that is consumed; generating replacement support information (60a, 260a, 360a, 660a, 760a, 860a, 960a, A60a) including the remaining amount of the consumable part and the replacement time when the replacement of the consumable part is required based on the physical quantity; and displaying the replacement support information on a display device (61).

[0163] Each of the multiple technical ideas described in this specification can be understood as a system, a method, a program, or a storage medium that stores a program.

Claims

1. A consumable part (12) that is a component installed in the equipment and is subject to wear and tear, A sensor (11) that detects a physical quantity that changes in relation to the wear of the aforementioned consumable parts, A control device (30) including at least one processor, the processor configured to generate replacement support information (60a, 260a, 360a, 660a, 760a, 860a, 960a, A60a) including the remaining amount of the consumable part and the replacement time when the consumable part is required, based on the physical quantity detected by the sensor, A display device (61) that displays the aforementioned exchange support information, The system includes a parts information storage unit (52) that stores parts information including quality information indicating the quality of the consumable parts, The control device is configured to determine a replacement plan based on quality information stored in the parts information storage unit, such that one consumable part is replaced with a consumable part of relatively higher quality, and other consumable parts are replaced with consumable parts of relatively lower quality.

2. The aforementioned consumable parts are components installed in equipment for processing workpieces, and are consumable parts that wear out according to the number of times the workpiece is processed. The system according to claim 1, wherein the remaining amount is the remaining number of times the consumable part can be used on the workpiece.

3. Furthermore, the aforementioned consumable part is one of several consumable parts used sequentially for a single workpiece. Furthermore, it includes a production information storage unit (51) that stores production information including process information indicating the order in which the plurality of consumable parts are used, The system according to claim 1, wherein the control device is configured to adjust the remaining amount and the replacement time based on the process information.

4. Furthermore, it includes a production information storage unit (51) that stores information including a production plan showing the number of workpieces to be processed, The aforementioned consumable part is one of several consumable parts that can be selectively used for a single workpiece. The system according to claim 1, wherein the control device is configured to adjust the distribution of workpieces to the plurality of consumable parts so that the production plan stored in the production information storage unit is satisfied and the replacement times for the plurality of consumable parts approach each other.

5. Furthermore, it includes a production information storage unit (51) that stores information including a production plan showing the number of items to be processed for each of several types of processed items, The aforementioned consumable part is one of a number of consumable parts corresponding to the aforementioned multiple types, The system according to claim 1, wherein the control device is configured to adjust the replacement times so that the replacement times of the plurality of consumable parts are close together, satisfying the production plan stored in the production information storage unit.

6. The aforementioned consumable part is one of several consumable parts. The system according to claim 1, wherein the control device is configured to set the same replacement time for one consumable part whose remaining amount has fallen below a predetermined allowable amount as for other consumable parts.

7. Furthermore, the system includes a parts information storage unit (52) that stores parts information including type information indicating whether the consumable parts are reusable or disposable, The system according to claim 1, wherein the control device is configured to generate different remaining amounts depending on whether the consumable part is of the reusable type or the disposable type, based on the type information stored in the part information storage unit.

8. Furthermore, it is equipped with an output device for sharing information among multiple business entities that make up the supply chain. The system according to claim 1, wherein the control device is configured to share information related to the replacement of the consumable parts among the multiple business entities.

9. To obtain physical quantities that change in relation to wear from consumable parts (12), Based on the aforementioned physical quantities, replacement support information (60a, 260a, 360a, 660a, 760a, 860a, 960a, A60a) is generated, including the remaining amount of the consumable parts and the time at which replacement of the consumable parts is required. The exchange support information is displayed on the display device (61), The parts information storage unit (52) stores parts information including quality information indicating the quality of the aforementioned consumable parts, A parts management method performed by a control device (30) including at least one processor, which includes determining a replacement plan based on quality information stored in the parts information storage unit, such that one consumable part is replaced with a consumable part of relatively higher quality and other consumable parts are replaced with consumable parts of relatively lower quality.

10. To obtain physical quantities that change in relation to wear from consumable parts (12), Based on the aforementioned physical quantities, replacement support information (60a, 260a, 360a, 660a, 760a, 860a, 960a, A60a) is generated, including the remaining amount of the consumable parts and the time at which replacement of the consumable parts is required. The exchange support information is displayed on the display device (61), The parts information storage unit (52) stores parts information including quality information indicating the quality of the aforementioned consumable parts, A program that causes a control device (30) including at least one processor to execute a replacement plan based on quality information stored in the aforementioned parts information storage unit, such as replacing one consumable part with a consumable part of relatively higher quality and replacing other consumable parts with consumable parts of relatively lower quality.