Analysis assistance device, analysis assistance method, and program

Abstract

The present invention appropriately makes a decision when abnormality occurs in equipment. This analysis assistance device comprises: a collection unit that collects maintenance records of equipment; an extraction unit that extracts, from the maintenance records, maintenance information including work information about measures taken in the event of abnormality in the equipment, symptoms of equipment abnormality, and the cause of equipment abnormality; an accumulation unit that accumulates the maintenance information; a creation unit that creates an analysis dictionary in which the symptoms of equipment abnormality are linked with at least one of the work information and data about the equipment abnormality; an analysis unit that analyzes the cause of the equipment abnormality on the basis of the analysis dictionary and at least one of the work information and monitoring data of the equipment state acquired by an acquisition unit, and creates an analysis report; and an output unit that outputs the analysis report.

Description

Analysis support device, analysis support method, and program

[0001] The present invention relates to an analysis support device, an analysis support method, and a program.

[0002] The records of the maintenance performed on the equipment can be used for the next maintenance and its planning, and are utilized for managing the equipment. Patent Document 1 discloses a maintenance improvement support system that presents an appropriate maintenance improvement introduction plan based on the user's improvement policy.

[0003] Japanese Patent Application Laid-Open No. 2020-181230

[0004] Conventionally, when a customer or other user has previously experienced an equipment abnormality, the user has dealt with the abnormality based on their own know-how. In factory automation (FA), multiple pieces of equipment are in operation, and equipment abnormalities can occur in a wide variety of ways, making it difficult to know which equipment manufacturer (device manufacturer) to contact and how to respond. Furthermore, even if a user contacts an equipment manufacturer, they often cannot receive a prompt response unless they confirm detailed information about the equipment, resulting in extended equipment downtime. Thus, when an abnormality occurs in equipment, it is necessary to make an appropriate judgment; however, the above-mentioned prior art does not allow for appropriate judgment when an abnormality occurs in equipment.

[0005] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a technique that enables appropriate judgment when an abnormality occurs in equipment.

[0006] An analysis support device according to one aspect of the present invention includes a collection unit that collects maintenance records of equipment, an extraction unit that extracts maintenance information from the maintenance records, including work information related to countermeasures when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment, a storage unit that stores the maintenance information, a creation unit that creates an analytical dictionary that links the work information, at least one of data related to the abnormality in the equipment, and the symptoms of the abnormality in the equipment, an analysis unit that analyzes the causes of the abnormality in the equipment based on the work information, at least one of monitoring data on the status of the equipment acquired by the acquisition unit, and the analytical dictionary, and creates an analysis report, and an output unit that outputs the analysis report. A user can check the analysis report to take immediate, provisional, or temporary measures against the abnormality in the equipment. This enables appropriate judgment when an abnormality occurs in the equipment.

[0007] The analysis support device includes an input unit that accepts input of the maintenance record from a user, and the input items of the maintenance record include at least the type of business, the name of the equipment, the name of the manufacturer of the equipment, and the error status of the equipment.

[0008] The analysis report is classified into one of (1) equipment-related errors, (2) multiple-cause errors including the equipment-related errors, or (3) new errors that do not fall into either the equipment-related errors or the multiple-cause errors. By checking the analysis report, the user can recognize whether the cause of the equipment abnormality is an equipment-related error, multiple-cause errors, or new cause. This allows the user to make more appropriate decisions when an abnormality occurs in the equipment.

[0009] An analysis support device according to one aspect of the present invention includes a collection unit that collects maintenance records of equipment, an extraction unit that extracts maintenance information from the maintenance records, including work information related to countermeasures when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment, a storage unit that stores the maintenance information, an improvement proposal unit that creates an improvement report related to improvements in the maintenance of the equipment based on the maintenance information, and an output unit that outputs the improvement report. A user can take permanent measures to address the abnormality in the equipment by checking the improvement report. This enables appropriate judgment when an abnormality occurs in the equipment.

[0010] The analysis support device includes an input unit that accepts input of the maintenance record from a user, and the input items of the maintenance record include at least the type of business, the name of the equipment, the name of the manufacturer of the equipment, and the error status of the equipment.

[0011] The improvement proposal unit creates introduction information for introducing a consultant who will provide consulting on improving the facility, the introduction information including at least one of the consultant's area of ​​expertise and workload status, and the output unit outputs the introduction information. If the user is able to improve the facility, the improvement proposal unit creates the improvement report and the output unit outputs the improvement report. If the user is unable to improve the facility, the improvement proposal unit creates the introduction information and the output unit outputs the introduction information. The user can make an inquiry to a consultant based on the introduction information and request the consultant to improve the facility. The user can appropriately select a consultant by selecting at least one of a plurality of consultants based on at least one of the consultant's area of ​​expertise and workload status.

[0012] The improvement report is classified into one of (1) equipment-related errors, (2) multiple-cause errors including the equipment-related errors, or (3) new errors that do not fall into either the equipment-related errors or the multiple-cause errors. By checking the improvement report, the user can recognize whether the cause of the equipment abnormality is an equipment-related error, multiple-cause errors, or new cause. This enables the user to more appropriately take permanent measures to address the equipment abnormality.

[0013] The present invention can be understood as an analysis support method including at least a part of the above-described processing, a program for causing a computer to execute at least a part of the above-described processing, or a computer-readable recording medium on which such a program is non-temporarily recorded. It can also be understood as an analysis support system including at least a part of the above-described processing. The above configurations and processing can be combined to constitute the present invention as long as no technical contradictions arise.

[0014] According to the present invention, it is possible to make an appropriate judgment when an abnormality occurs in equipment. According to the present invention, it is possible to accumulate know-how on equipment maintenance and to make an immediate judgment when an abnormality occurs in equipment, thereby improving the equipment's uptime (production efficiency). In addition, the burden on maintenance workers is reduced. Furthermore, unnecessary inquiries from users to equipment manufacturers are reduced, and equipment manufacturers can respond appropriately to equipment abnormalities, thereby reducing the burden on the equipment manufacturers.

[0015] Fig. 1 is a diagram showing the overall configuration of an analysis support system to which the present invention is applied. Fig. 2 is a functional block diagram of an analysis support device. Fig. 3 is a diagram showing an example of a maintenance record created in a dedicated file format. Fig. 4 is a diagram showing an example of an accumulation unit. Fig. 5 is a diagram showing an example of an analysis report. Fig. 6 is a diagram showing an example of a storage unit. Fig. 7 is a diagram showing an example of input items for the maintenance record.

[0016] Application examples and embodiments will be described below with reference to the drawings. The application examples and embodiments described below are aspects of the present application and do not limit the scope of the rights of the present application.

[0017] <Application Example> FIG. 1 is a diagram showing the overall configuration of an analysis support system (maintenance system) to which the present invention is applied. The analysis support system includes an analysis support device 1, a control device 2, and one or more sensors 3. The analysis support device 1 is communicatively connected to the control device 2 via a wired or wireless connection. The analysis support device 1 is, for example, an industrial personal computer (IPC). The control device 2 is communicatively connected to equipment 4 via a wired or wireless connection. The control device 2 is, for example, a programmable logic controller (PLC) and controls the equipment 4. The equipment 4 is, for example, a production device, a processing device, or the like, but is not limited thereto. The control device 2 may be one or more control devices 2. The equipment 4 may be one or more equipment 4. The control device 2 is communicatively connected to one or more sensors 3 via a wired or wireless connection. The one or more sensors 3 measure various parameters during operation of the equipment 4. Measurement values ​​measured by the one or more sensors 3 are sent to the control device 2. The analysis support device 1 acquires measurement values ​​from the control device 2 as monitoring data of the state of the equipment 4. For example, when a measurement value measured by one or more sensors 3 exceeds a threshold, the analysis support device 1 and the control device 2 detect an abnormality in the equipment 4. An abnormality in the equipment 4 is a state in which the equipment 4 is no longer normal.

[0018] One or more information processing devices 5 are communicatively connected to the analysis support device 1 wirelessly or via a wire. The information processing device 5 is, for example, a smartphone, a tablet terminal, a personal computer, or a smartwatch. When the analysis support device 1 detects an abnormality in the equipment 4, it sends a notification indicating that an abnormality has occurred in the equipment 4 to the information processing device 5. The user recognizes that an abnormality has occurred in the equipment 4 by checking the message in the notification. When an abnormality has occurred in the equipment 4, the user performs countermeasure work and creates a maintenance record for the equipment 4. The countermeasure work is work to alleviate the symptoms of the abnormality in the equipment 4 when an abnormality has occurred in the equipment 4 and restore the equipment 4 to a temporary operable state or a normal state. The symptoms of the equipment 4 are conditions in which an abnormality in the equipment 4 becomes apparent and affects production, quality, and safety. Symptoms of an abnormality in the equipment 4 include, but are not limited to, a high temperature at a specific location of the equipment 4, worn parts of the equipment 4, broken parts of the equipment 4, deteriorated insulation in the equipment 4, deteriorated or disconnected heaters in the equipment 4, worn or damaged cutting tools in the equipment 4, and abnormal current in the equipment 4. Examples of symptoms of an abnormality in the equipment 4 include, but are not limited to, an inability to obtain the output required for the conveyor to operate to a normal position, an inability to process an object due to wear of a cutting tool, vibration causing the processed surface precision to deviate from the standard value, poor welding due to insufficient welding output, a fire caused by excessive temperature rise, and electric shock due to leakage current. The user may create the maintenance record in a data file or on a paper form (paper medium). The maintenance record includes work information regarding countermeasures to be taken when an abnormality occurs in the equipment 4, and maintenance information including symptoms of the abnormality in the equipment 4 and the causes of the abnormality in the equipment 4.

[0019] The analysis support device 1 collects maintenance records and extracts from the maintenance records maintenance information including work information related to countermeasures to be taken when an abnormality occurs in the equipment 4, symptoms of the abnormality in the equipment 4, and causes of the abnormality in the equipment 4. The analysis support device 1 includes a database (storage unit) 6. The analysis support device 1 stores the maintenance information extracted from the maintenance records in the database 6. The analysis support device 1 creates an analysis dictionary that links at least one of the work information and data related to the abnormality in the equipment 4 with symptoms of the abnormality in the equipment 4 when an abnormality occurs in the equipment 4. The data related to the abnormality in the equipment 4 may be data related to measurement values ​​measured by one or more sensors 3.

[0020] The analysis support device 1 analyzes the cause of the abnormality in the equipment 4 based on at least one of the work information and the monitoring data and the analytical dictionary, and creates an analysis report. The analysis report is a report that allows the user to take immediate, provisional, or temporary measures in response to the abnormality in the equipment 4. The analysis support device 1 outputs the analysis report. The analysis support device 1 may output the analysis report by attaching it to an email or a chat, or may output the analysis report directly. The information processing device 5 receives the analysis report output from the analysis support device 1. The user checks the analysis report displayed on the screen of a display (display unit) in the information processing device 5. The analysis support device 1 may print and output the analysis report on paper. By checking the analysis report, the user can take immediate, provisional, or temporary measures in response to the abnormality in the equipment 4. This makes it possible to make appropriate decisions when an abnormality occurs in the equipment 4.

[0021] The analysis support device 1 creates an improvement report regarding improvements to the maintenance of the equipment 4 based on the maintenance information. The improvement report is a report that allows the user to take permanent measures to address an abnormality in the equipment 4. The analysis support device 1 outputs the improvement report. The analysis support device 1 may output the improvement report by attaching it to an email or chat, or may directly output the analysis report. The information processing device 5 receives the improvement report output from the analysis support device 1. The user checks the improvement report displayed on the display screen of the information processing device 5. The analysis support device 1 may print and output the improvement report on paper media. By checking the improvement report, the user can take permanent measures to address an abnormality in the equipment 4. This makes it possible to make appropriate decisions when an abnormality occurs in the equipment 4.

[0022] <Description of the embodiment> The analysis support device 1 may be configured with dedicated equipment or a general-purpose computer. The analysis support device 1 includes hardware resources such as a processor, memory, and storage. The processor may be a general-purpose processor such as a CPU (Central Processing Unit) or an MPU (Micro Processing Unit), or may be a dedicated processor. The processor may be configured as a single circuit, or may be configured by combining multiple independent circuits. The memory may be RAM (Random Access Memory). The storage may be a non-volatile storage device such as ROM (Read Only Memory) or flash memory.

[0023] FIG. 2 is a functional block diagram of the analysis support device 1. The analysis support device 1 mainly includes a collection unit 10, an extraction unit 11, a storage unit 12, an acquisition unit 13, a monitoring unit 14, a creation unit (first creation unit) 15, an analysis unit 16, an improvement proposal unit 17, an output unit 18, a memory unit 19, an input unit 20, and a maintenance record creation unit (second creation unit) 21. The functions of each processing unit (functional unit) of the analysis support device 1 are realized by loading a program stored in a storage device into memory and executing the program using a processor. Not all of the components of the analysis support device 1 shown in FIG. 2 are essential, and components of the analysis support device 1 may be added or removed as appropriate. Some or all of the functions of the analysis support device 1 may be implemented using circuits such as an application-specific integrated circuit (ASIC) or a field-programmable gate array (FPGA). Alternatively, some or all of the functions of the analysis support device 1 may be executed by a cloud server or other device.

[0024] The collection unit 10 collects maintenance records of the equipment 4. The user may handwrite the maintenance records on a paper form (paper medium). For example, the user writes the maintenance records, such as the type of industry, the name of the equipment 4, the name of the manufacturer of the equipment 4, the time when an abnormality occurred in the equipment 4, the error status of the equipment 4, the content of the countermeasure work, the start time of the countermeasure work, the end time of the countermeasure work, and the time required for the countermeasure work (response time), on the paper form. The error status of the equipment 4 includes symptoms of the equipment 4 when an abnormality occurs in the equipment 4 (symptoms of the abnormality in the equipment 4), causes of the equipment 4 when an abnormality occurs in the equipment 4 (causes of the abnormality in the equipment 4), and the like. Without being limited to these examples, the maintenance records may also include the model, years of operation, and production item of the equipment 4, the name and cause of the malfunction of the equipment 4, repair parts, the name of the worker, years of experience, age, and years of maintenance work. The maintenance record may also include the company name, facility name, and process name of the equipment 4, the circumstances under which the abnormality occurred, specific symptoms of the abnormality, the cause of the abnormality, specific recovery work, the time required to recover from the occurrence of the abnormality, the man-hours required to recover from the occurrence of the abnormality (number of people x hours), and repair costs. A user may use a camera provided in the information processing device 5 to photograph a paper form on which the maintenance record is written. The information processing device 5 may convert image data into text data by performing OCR (Optical Character Recognition) processing. The collection unit 10 may collect the maintenance records by acquiring the text data of the maintenance records from the information processing device 5.

[0025] The user may create a maintenance record in a general-purpose file format using a general-purpose application (e.g., a spreadsheet application) installed on the information processing device 5. For example, the user may use the general-purpose application to input a maintenance record such as the type of business, the name of the equipment 4, the name of the manufacturer of the equipment 4, the time when an abnormality occurred in the equipment 4, the measurement value, the error status of the equipment 4, the content of the countermeasure work, the start time of the countermeasure work, the end time of the countermeasure work, and the time required for the countermeasure work (response time), thereby creating a general-purpose file containing data of the maintenance record. The collection unit 10 may collect the maintenance records by acquiring a general-purpose file containing data of the maintenance record from the information processing device 5.

[0026] The user may create a maintenance record in a dedicated file format using a dedicated application installed in the information processing device 5. For example, the user may use the dedicated application to input a maintenance record such as the name of the equipment 4, the name of the manufacturer of the equipment 4, the time when the abnormality occurred in the equipment 4, the measurement value, the error status of the equipment 4, the content of the countermeasure work, the start time of the countermeasure work, the end time of the countermeasure work, and the time required for the countermeasure work (response time), thereby creating a dedicated file containing data of the maintenance record.

[0027] FIG. 3 is a diagram showing an example of a maintenance record created in a dedicated file format. In FIG. 3 , a dedicated file is created containing maintenance record data such as the type of business, the name of the equipment 4, the name of the manufacturer of the equipment 4, the date and time when an abnormality occurred in the equipment 4, measurement values, the error status of the equipment 4, the content of the countermeasure work, the start time of the countermeasure work, the end time of the countermeasure work, and the time required for the countermeasure work (response time). In addition, photographic data of the equipment 4 when an abnormality occurred in the equipment 4, and photographic data of the equipment 4 when the countermeasure work was performed may be attached to the maintenance record. The user attaches the photographic data to the maintenance record by taking a photograph using a camera provided in the information processing device 5. The dedicated application may automatically input the name of the equipment 4, the name of the manufacturer of the equipment 4, the date and time when the abnormality occurred in the equipment 4, and the measurement values ​​by acquiring the name of the equipment 4, the name of the manufacturer of the equipment 4, the date and time when the abnormality occurred in the equipment 4, and the measurement values ​​from the control device 2. The collection unit 10 may collect the maintenance records by acquiring a dedicated file containing the maintenance record data from the information processing device 5.

[0028] The extraction unit 11 extracts, from the maintenance records, maintenance information including work information related to response work when an abnormality occurs in the equipment 4, symptoms of the abnormality in the equipment 4, and causes of the abnormality in the equipment 4. The extraction unit 11 may generate an extraction model by artificial intelligence (AI) or machine learning, and extract the maintenance information from the maintenance records using the extraction model. The maintenance information may also include time information related to the abnormality in the equipment 4. The time information related to the abnormality in the equipment 4 includes, but is not limited to, the stop time of the equipment 4, the time when the operation of the equipment 4 stopped, the time when the operation of the equipment 4 resumed, the time when the response work started, the time when the response work ended, and the time required for the response work (response time).

[0029] The storage unit 12 stores maintenance information. Fig. 4 is a diagram showing an example of the storage unit 12. The storage unit 12 has a plurality of individual company databases (DB) 30, an integrated database (DB) 31, and an equipment database (DB) 32. The plurality of individual company databases 30 store maintenance information for each individual company. The integrated database 31 stores all of the maintenance information in the plurality of individual company databases 30. The equipment database 32 stores maintenance information for each equipment 4.

[0030] The acquisition unit 13 acquires monitoring data on the state of the equipment 4. The acquisition unit 13 acquires measurement values ​​measured by one or more sensors 3 as monitoring data on the state of the equipment 4. The monitoring unit 14 determines whether or not an abnormality has occurred in the equipment 4 based on the monitoring data. If the monitoring data satisfies a predetermined condition, the monitoring unit 14 detects an abnormality in the equipment 4. Examples of cases in which the monitoring data satisfies the predetermined condition are shown below, but are not limited to these examples.

[0031] The monitoring unit 14 may detect an abnormality in the equipment 4 when the measurement value exceeds a threshold value. The monitoring unit 14 may count the number of times the measurement value in a unit time exceeds a threshold value, and when the counted number is equal to or greater than a predetermined number, detect an abnormality in the equipment 4. The monitoring unit 14 may detect an abnormality in the equipment 4 when the measurement value is equal to or less than the threshold value. The monitoring unit 14 may count the number of times the measurement value in a unit time is equal to or less than the threshold value, and when the counted number is equal to or greater than a predetermined number, detect an abnormality in the equipment 4. When the monitoring unit 14 detects an abnormality in the equipment 4, it sends a notification to the information processing device 5 indicating that an abnormality has occurred in the equipment 4.

[0032] The creation unit 15 creates an analysis dictionary that links at least one of the work information and data related to an abnormality in the equipment 4 with symptoms of the abnormality in the equipment 4 when an abnormality occurs in the equipment 4. The data related to the abnormality in the equipment 4 may be data related to a measurement value when the measurement value exceeds a threshold. The threshold can be set for each user. The data related to the abnormality in the equipment 4 may also be data related to a measurement value when the measurement value is equal to or less than the threshold. The data related to the measurement value is, for example, but is not limited to, raw data of the measurement value, data indicating that the measurement value has exceeded the threshold, data indicating that the measurement value is less than the threshold, or evaluation data when the measurement value is evaluated. The evaluation data is, for example, but is not limited to, the number of times the measurement value exceeds the threshold in a unit time or the number of times the measurement value is equal to or less than the threshold in a unit time.

[0033] The analysis unit 16 analyzes the cause of the abnormality in the equipment 4 based on at least one of the work information and the monitoring data acquired by the acquisition unit 13, and the analysis dictionary, and creates an analysis report. The analysis unit 16 may generate an analysis model by generative AI or machine learning, and create the analysis report using the analysis model. When the analysis report is created by the analysis unit 16, the output unit 18 outputs the analysis report.

[0034] FIG. 5 is a diagram showing an example of an analysis report. A balloon area Z1 shows the results of analysis performed by the analysis unit 16. A dotted-line rectangular area Z2 displays multiple candidates estimated as the cause of the abnormality in the equipment 4, along with their ranking. In FIG. 5, the cause (misalignment) is selected, and therefore the balloon area Z3 displays the number of maintenance records related to the cause (misalignment). When the cause (sealing jam) is selected, the balloon area Z3 displays the number of maintenance records related to the cause (sealing jam). When the cause (bearing grease shortage) is selected, the balloon area Z3 displays the number of maintenance records related to the cause (bearing grease shortage). A file of a maintenance record related to the selected cause may be attached to the analysis report. A plurality of files may be attached to the analysis report in descending order of relevance.

[0035] The analysis report may be classified into any of (1) equipment-caused errors, (2) multiple-caused errors including equipment-caused errors, or (3) new errors that do not fall into either equipment-caused errors or multiple-caused errors. Multiple factors include equipment factors and human factors, environmental factors, component factors, etc. other than equipment factors. If the cause of the abnormality in the equipment 4 is an equipment factor, the analysis unit 16 creates an analysis report classified as an equipment-caused error. If the cause of the abnormality in the equipment 4 is multiple factors, the analysis unit 16 creates an analysis report classified as an error of multiple factors. If the cause of the abnormality in the equipment 4 is a new factor, the analysis unit 16 creates an analysis report classified as an error of new factors. A new factor is a factor that does not fall into either equipment factors or multiple factors.

[0036] By checking the analysis report, the user can recognize whether the cause of the abnormality in the equipment 4 is an equipment factor, a combination of factors, or a new factor. This allows the user to make a more appropriate decision when an abnormality occurs in the equipment 4. If the cause of the abnormality in the equipment 4 is an equipment factor, the user can discover the cause of the abnormality in the equipment 4 in a short period of time by investigating the cause of the abnormality in the equipment 4 presented in the analysis report. Furthermore, if the cause of the abnormality in the equipment 4 is an equipment factor, the user may make an inquiry to the equipment manufacturer based on monitoring data (measurement values) of the status of the equipment 4. If the cause of the abnormality in the equipment 4 is a combination of factors, the user can discover the cause of the abnormality in the equipment 4 in a short period of time by investigating the cause of the abnormality in the equipment 4 presented in the analysis report as well as human factors, environmental factors, component factors, etc. Furthermore, if the cause of the abnormality in the equipment 4 is a combination of factors, the user may make an inquiry to the equipment manufacturer based on monitoring data (measurement values) of the status of the equipment 4. If the cause of the abnormality in the equipment 4 is a new factor, the user may request a third party to investigate.

[0037] The improvement proposing unit 17 creates an improvement report regarding improvements to the maintenance of the equipment 4 based on the maintenance information. The contents of the improvement report may be displayed using at least one of a Pareto chart, a cause-and-effect diagram, a graph, a histogram, a scatter diagram, a control chart, and a checklist. The improvement proposing unit 17 may generate an improvement proposal model using generative AI or machine learning, and create the improvement report using the improvement proposal model. When the improvement report is created by the improvement proposing unit 17, the output unit 18 outputs the improvement report.

[0038] The improvement report may be classified into any of (1) equipment-related errors, (2) multiple-cause errors including equipment-related errors, or (3) new errors that do not fall into either equipment-related errors or multiple-cause errors. If the cause of the abnormality in the equipment 4 is an equipment-related error, the improvement proposing unit 17 creates an improvement report classified as an equipment-related error. If the cause of the abnormality in the equipment 4 is multiple-cause errors including equipment-related errors, the improvement proposing unit 17 creates an improvement report classified as an error of multiple causes. If the cause of the abnormality in the equipment 4 is a new factor, the improvement proposing unit 17 creates an improvement report classified as an error of a new factor.

[0039] By checking the improvement report, the user can recognize whether the cause of the abnormality in the equipment 4 is an equipment factor, a multiple factor, or a new factor. This enables the user to more appropriately take permanent measures to address the abnormality in the equipment 4. If the cause of the abnormality in the equipment 4 is an equipment factor, the user may take permanent measures to address the abnormality in the equipment 4 based on the contents of the improvement report. Furthermore, if the cause of the abnormality in the equipment 4 is an equipment factor, the user may make an inquiry to the equipment manufacturer based on monitoring data (measurement values) of the status of the equipment 4. If the cause of the abnormality in the equipment 4 is multiple factors, the user may take permanent measures to address the abnormality in the equipment 4 based on the contents of the improvement report, and may also take permanent measures to address human factors, environmental factors, component factors, etc. Furthermore, if the cause of the abnormality in the equipment 4 is multiple factors, the user may make an inquiry to the equipment manufacturer based on monitoring data (measurement values) of the status of the equipment 4. If the cause of the abnormality in the equipment 4 is a new factor, the user may request a third party to investigate.

[0040] The improvement proposal unit 17 creates introduction information for introducing consultants (improvement consultants) who will provide consulting on improving the facility 4, the introduction information including at least one of the consultant's areas of expertise and workload status. When the introduction information is created by the improvement proposal unit 17, the output unit 18 outputs the introduction information. The introduction information may include information on multiple consultants. If the user is able to improve the facility 4, the improvement proposal unit 17 creates an improvement report, and the output unit 18 outputs the improvement report. If the user is unable to improve the facility 4, the improvement proposal unit 17 creates introduction information, and the output unit 18 outputs the introduction information. This allows the user to make an inquiry to a consultant based on the introduction information and request the consultant to improve the facility 4.

[0041] The referral information includes at least one of the consultant's specialty and workload status. The user may select at least one of multiple consultants based on at least one of the consultant's specialty and workload status. For example, the user can select a consultant who is skilled in the electrical field or a consultant who is skilled in the mechanical field. This allows the user to appropriately select a consultant. In this way, it is possible to place and receive orders for consulting services for improving facility 4 based on at least one of the consultant's specialty and workload status.

[0042] The storage unit 19 stores various types of data and information. Fig. 6 is a diagram showing an example of the storage unit 19. The storage unit 19 has a consultant information database 40. The consultant information database 40 stores information on consultants' areas of expertise and information on the consultants' workload status. The information on consultants' areas of expertise and information on the consultants' workload status in the consultant information database 40 is updated as needed.

[0043] The input unit 20 accepts maintenance record input from a user. FIG. 7 is a diagram showing an example of maintenance record input items. The maintenance record input items include at least "industry type," "equipment name," "equipment manufacturer name," and "equipment error status." Furthermore, the maintenance record input items include "time of equipment abnormality occurrence," "measurement value," "details of countermeasure work," "start time of countermeasure work," "end time of target work," and "response time." The maintenance record input items are not limited to these and may include other items. The maintenance record input items may include the model, years of operation, and production item of the equipment 4, the name and cause of the equipment 4 fault, repair parts, the worker's name, years of experience, age, and years of maintenance work. The maintenance record input items may also include the company name, facility name, and process name of the equipment 4, the occurrence status of the abnormality, specific symptoms of the abnormality, the cause of the abnormality, specific recovery work, the time required for recovery from the occurrence of the abnormality, the man-hours required for recovery from the occurrence of the abnormality (many people x hours), and repair costs. For example, input items for the maintenance record may be displayed on the display screen of the information processing device 5, and the user may use the information processing device 5 to input information according to the input items of the maintenance record. The input unit 20 or a dedicated application installed on the information processing device 5 may acquire information and data relating to each of the input items, "name of the equipment," "name of the equipment manufacturer," "time when the equipment abnormality occurred," and "measured value," from the control device 2. In this case, information and data relating to these input items are pre-entered into each of the input items, "name of the equipment manufacturer," "time when the equipment abnormality occurred," and "measured value," on the display screen of the information processing device 5. This simplifies the user's input work.

[0044] The input items for the maintenance record may also include work procedures and tools. The tools may be selectable. For example, a plurality of tools may be displayed on the display screen of the information processing device 5, and the user may select at least one of the plurality of tools. The input unit 20 may also accept input of photographic data, drawing data, video data, etc. from the user. When the input unit 20 accepts input of a maintenance record from the user, the maintenance record creation unit 21 creates a maintenance record in a dedicated file format. When the input unit 20 accepts input of photographic data, drawing data, video data, manuals, etc. from the user, the photographic data, drawing data, video data, manuals, etc. are attached to the maintenance record in the dedicated file format. The user may take a photograph using a camera provided in the information processing device 5, and the photographic data may be attached to the maintenance record in the dedicated file format.

[0045] The analysis support system makes it possible to accumulate know-how on the maintenance of FA equipment and to make instant decisions when an abnormality occurs in the FA equipment, thereby improving the uptime (production efficiency) of the FA equipment. Furthermore, the analysis support system makes it possible to take permanent measures against an abnormality in the FA equipment in a short period of time, thereby improving the uptime (production efficiency) of the FA equipment. It also reduces the burden on maintenance workers. Furthermore, it reduces unnecessary inquiries from users to equipment manufacturers, and allows equipment manufacturers to respond appropriately to abnormalities in the FA equipment, thereby reducing the burden on the equipment manufacturers.

[0046] The present invention can be understood as an analysis support method including at least a part of the above-described processing, a program for causing a computer to execute at least a part of the above-described processing, or a computer-readable recording medium on which such a program is non-temporarily recorded. It can also be understood as an analysis support system including at least a part of the above-described processing. The above configurations and processing can be combined to constitute the present invention as long as no technical contradictions arise.

[0047] <Supplementary Note 1> An analysis support device (1) comprising: a collection unit (10) that collects maintenance records of equipment (4); an extraction unit (11) that extracts, from the maintenance records, maintenance information including work information related to response work when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage unit (12) that stores the maintenance information; a creation unit (15) that creates an analysis dictionary that links the work information and at least one of data related to the abnormality in the equipment (4) with symptoms of the abnormality in the equipment (4); an analysis unit (16) that analyzes causes of the abnormality in the equipment (4) based on the work information, at least one of monitoring data of the status of the equipment (4) acquired by an acquisition unit (13), and the analysis dictionary, and creates an analysis report; and an output unit (18) that outputs the analysis report. <Supplementary Note 2> The analysis support device (1) according to Supplementary Note 1, further comprising an input unit (20) that accepts input of the maintenance record from a user, wherein input items of the maintenance record include at least the type of business, the name of the equipment (4), the name of the manufacturer of the equipment (4), and the error status of the equipment (4). <Supplementary Note 3> The analysis support device (1) according to Supplementary Note 1 or 2, wherein the analysis report is classified into either (1) errors caused by equipment factors, (2) errors caused by multiple factors including the equipment factors, or (3) new errors that do not fall into either the errors caused by the equipment factors or the errors caused by the multiple factors. <Supplementary Note 4> An analysis support device (1) comprising: a collection unit (10) that collects maintenance records of equipment (4), an extraction unit (11) that extracts maintenance information from the maintenance records, the maintenance information including work information related to countermeasures when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4), a storage unit (12) that stores the maintenance information, an improvement proposal unit (17) that creates an improvement report related to improvements to the maintenance of the equipment (4) based on the maintenance information, and an output unit (18) that outputs the improvement report. <Supplementary Note 5> The analysis support device (1) according to Supplementary Note 4 further comprises an input unit (20) that accepts input of the maintenance records from a user, and input items of the maintenance records include at least the type of industry, the name of the equipment (4), the name of a manufacturer of the equipment (4), and an error status of the equipment (4).<Supplementary Note 6> The analysis support device (1) according to Supplementary Note 4 or 5, wherein the improvement proposal unit (17) creates referral information for introducing a consultant who will provide consulting on improving the facility (4), the referral information including at least one of the consultant's area of ​​expertise and a workload status, and the output unit (18) outputs the referral information. <Supplementary Note 7> The analysis support device (1) according to Supplementary Note 6, wherein if the user can improve the facility (4), the improvement proposal unit (17) creates the improvement report and the output unit (18) outputs the improvement report, and if the user cannot improve the facility (4), the improvement proposal unit (17) creates the referral information and the output unit (18) outputs the referral information. <Supplementary Note 8> The analysis support device (1) according to any one of Supplementary Notes 4 to 7, wherein the improvement report is classified into one of (1) errors caused by equipment factors, (2) errors caused by multiple factors including the equipment factors, or (3) new errors that do not fall into either the errors caused by equipment factors or the errors caused by multiple factors. <Supplementary Note 9> An analysis support method in which a computer executes the following steps: a step of collecting maintenance records of equipment (4); an extraction step of extracting, from the maintenance records, maintenance information including work information related to countermeasures to be taken when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage step of storing the maintenance information in a storage unit (12); a creation step of creating an analysis dictionary linking the work information, at least one of data related to the abnormality in the equipment (4), and symptoms of the abnormality in the equipment (4); an analysis step of analyzing causes of the abnormality in the equipment (4) based on the work information, at least one of monitoring data on the status of the equipment (4) acquired by an acquisition unit (13), and the analysis dictionary, and creating an analysis report; and an output step of outputting the analysis report.<Supplementary Note 10> An analysis support method in which a computer executes the following steps: a step of collecting maintenance records of equipment (4); an extraction step of extracting, from the maintenance records, maintenance information including work information related to countermeasures when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); a storage step of storing the maintenance information in a storage unit (12); an improvement proposal step of creating an improvement report related to improvements in the maintenance of the equipment (4) based on the maintenance information; and an output step of outputting the improvement report. <Supplementary Note 11> A program for causing a computer to execute the following steps: collecting maintenance records of equipment (4); extracting, from the maintenance records, maintenance information including work information related to countermeasures when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); storing, in a storage unit (12), the maintenance information; creating, in a storage unit (12), an analysis step of analyzing causes of the abnormality in the equipment (4) based on the work information, at least one of monitoring data on the status of the equipment (4) acquired by an acquisition unit (13), and the analysis dictionary, and creating an analysis report; and outputting, in a storage unit (12), the maintenance information including work information related to countermeasures when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); <Supplementary Note 12> A program for causing a computer to execute the following steps: collecting maintenance records of equipment (4); extracting maintenance information from the maintenance records, the maintenance information including work information related to countermeasures to be taken when an abnormality occurs in the equipment (4), symptoms of the abnormality in the equipment (4), and causes of the abnormality in the equipment (4); storing the maintenance information in a storage unit (12); making an improvement proposal step of creating an improvement report related to improvements in the maintenance of the equipment (4) based on the maintenance information; and outputting the improvement report.

[0048] 1: Analysis support device 2: Control device 3: Sensor 4: Equipment 5: Information processing device 6: Database 10: Collection unit 11: Extraction unit 12: Storage unit 13: Acquisition unit 14: Monitoring unit 15: Creation unit 16: Analysis unit 17: Improvement proposal unit 18: Output unit 19: Storage unit 20: Input unit 21: Maintenance record creation unit 30: Individual company database 31: Integrated database 32: Equipment database 40: Consultant information database

Claims

1. An analysis support device comprising: a collection unit that collects maintenance records of equipment; an extraction unit that extracts from the maintenance records maintenance information including work information related to response work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage unit that stores the maintenance information; a creation unit that creates an analysis dictionary that links the work information, at least one of data related to the abnormality in the equipment, and symptoms of the abnormality in the equipment; an analysis unit that analyzes causes of the abnormality in the equipment based on the work information, at least one of monitoring data of the equipment status acquired by the acquisition unit, and the analysis dictionary, and creates an analysis report; and an output unit that outputs the analysis report.

2. An analysis support device as described in claim 1, comprising an input unit that accepts input of the maintenance record from a user, and the input items of the maintenance record include at least the industry type, the name of the equipment, the manufacturer name of the equipment, and the error status of the equipment.

3. The analysis support device according to claim 1 or 2, wherein the analysis report is classified into one of (1) errors caused by equipment factors, (2) errors caused by multiple factors including the equipment factors, or (3) new errors that do not fall into either the equipment factors or the multiple factors.

4. An analysis support device comprising: a collection unit that collects maintenance records of equipment; an extraction unit that extracts maintenance information from the maintenance records, including work information related to response work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage unit that stores the maintenance information; an improvement proposal unit that creates an improvement report related to improvements to the maintenance of the equipment based on the maintenance information; and an output unit that outputs the improvement report.

5. An analysis support device as described in claim 4, comprising an input unit that accepts input of the maintenance record from a user, and the input items of the maintenance record include at least the industry type, the name of the equipment, the manufacturer name of the equipment, and the error status of the equipment.

6. The analysis support device according to claim 4, wherein the improvement proposal unit creates introduction information for introducing a consultant who will provide consulting on improving the facility, the introduction information including at least one of the consultant's areas of expertise and workload status, and the output unit outputs the introduction information.

7. The analysis support device according to claim 6, wherein, if the user is able to improve the equipment, the improvement suggestion unit creates the improvement report and the output unit outputs the improvement report; and if the user is unable to improve the equipment, the improvement suggestion unit creates the introduction information and the output unit outputs the introduction information.

8. The analysis support device according to any one of claims 4 to 7, wherein the improvement report is classified into one of (1) errors caused by equipment factors, (2) errors caused by multiple factors including the equipment factors, or (3) new errors that do not fall into either the equipment factors or the multiple factors.

9. An analysis support method in which a computer executes the following steps: collecting maintenance records of equipment; extracting from the maintenance records maintenance information including work information related to response work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; storing the maintenance information in a storage unit; creating an analysis dictionary linking the work information, at least one of data related to the abnormality in the equipment, and symptoms of the abnormality in the equipment; analyzing the causes of the abnormality in the equipment based on the work information, at least one of monitoring data of the equipment status acquired by the acquisition unit, and the analysis dictionary, and creating an analysis report; and outputting the analysis report.

10. An analysis support method in which a computer executes the following steps: a step of collecting maintenance records of equipment; an extraction step of extracting from the maintenance records maintenance information including work information related to response work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; a storage step of storing the maintenance information in a storage unit; an improvement proposal step of creating an improvement report related to improvements to the maintenance of the equipment based on the maintenance information; and an output step of outputting the improvement report.

11. A program for causing a computer to execute the following steps: collecting maintenance records of equipment; extracting from the maintenance records maintenance information including work information related to response work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; storing the maintenance information in a storage unit; creating an analysis dictionary linking the work information, at least one of data related to the abnormality in the equipment, and symptoms of the abnormality in the equipment; analyzing the causes of the abnormality in the equipment based on the work information, at least one of monitoring data of the equipment status acquired by the acquisition unit, and the analysis dictionary, and creating an analysis report; and outputting the analysis report.

12. A program for causing a computer to execute the following steps: collecting maintenance records of equipment; extracting from the maintenance records maintenance information including work information regarding response work when an abnormality occurs in the equipment, symptoms of the abnormality in the equipment, and causes of the abnormality in the equipment; storing the maintenance information in a storage unit; improving proposal step creating an improvement report regarding improvements to the maintenance of the equipment based on the maintenance information; and output step outputting the improvement report.

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