Work Instruction Feedback for Non-Networked Controller Operation
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Solution Overview
Problem
Existing production plant controllers that are not network-connected require manual operation and data recording, lacking digitalization and efficient data utilization, and physical modifications to connect them to a network are costly and complex.
Innovation Solution
A work management system that includes a server device, worker terminal, and controller, utilizing cameras and eye-tracking sensors to acquire and analyze operation data, providing real-time work instructions and notifications to workers without network connection, enabling digital data management and centralized data integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If controllers are connected to a network, then data utilization and digitalization are improved, but device complexity and cost of physical modification increase
Solution Approach 1:
The system creates a virtual copy of the controller's operation data and transmits it to a server device via a terminal device. This allows data utilization and digitalization without physically modifying the controller or connecting it to the network, thus resolving the contradiction between data utilization improvement and device complexity increase
Solution Approach 2:
A terminal device serves as an intermediary between the controller and the server device. The terminal device captures operation data from the controller and transmits it to the server, enabling data utilization without direct network connection to the controller, thereby avoiding physical modification complexity
2Device complexity
If manual operation is performed on non-networked controllers, then device complexity is reduced, but productivity and data utilization deteriorate
Solution Approach 1:
The server device provides feedback to the worker by displaying work instructions based on analyzed operation data. This automated feedback system improves productivity by guiding workers through standardized procedures without requiring complex system modifications to the controllers
Solution Approach 2:
The system performs preliminary analysis of operation data to determine appropriate work instructions before presenting them to the worker. This preliminary processing automates decision-making and improves productivity while maintaining simple device configuration
3Productivity
If work instructions are provided in real-time, then productivity is improved, but information processing complexity increases
Solution Approach 1:
The system performs partial information processing by analyzing only the necessary operation data to determine work instructions, rather than processing all possible data. This selective analysis improves productivity while keeping information processing complexity manageable through focused data handling
Data Source
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AI summary
A server device (10) acquires operation data for identifying operation that is performed on a controller (30) by a worker (W) in accordance with a work instruction on a predetermined work process related to the controller (30) that is operated by the worker (W), analyzes the operation data, determines a notification content for the worker (W), and notifies the worker (W) of the determined notification content.