Equipment Element Maintenance Using Rolling Error Rate Analysis
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Solution Overview
Problem
Existing equipment element maintenance systems for manufacturing equipment, such as component mounters, lack an efficient method to determine maintenance necessity, often leading to unnecessary or delayed maintenance due to reliance on cumulative error counts and lack of real-time operational data analysis.
Innovation Solution
An equipment element maintenance analysis system that includes a history information acquirer, error rate calculator, maintenance determiner, and notifier, which analyzes operation history data to calculate a latest error rate and determine maintenance necessity based on predetermined thresholds, thereby identifying equipment elements requiring maintenance efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If service is determined based on cumulative error counts reaching a predetermined threshold, then service timing can be standardized, but unnecessary maintenance occurs when errors are naturally recovered or preventive maintenance is already performed
Solution Approach 1:
The patent transitions from static cumulative error counting to dynamic error rate monitoring. The system continuously calculates error rates over rolling time windows (e.g., last 24 hours, 7 days) and compares them against thresholds, allowing maintenance decisions to adapt to real-time equipment performance changes rather than following fixed cumulative thresholds
Solution Approach 2:
The patent changes the parameter from cumulative error count to error rate (errors per unit time). This parameter transformation enables the system to distinguish between temporary error spikes and sustained degradation patterns, allowing for more accurate determination of actual maintenance needs based on temporal error behavior
2Ease of operation
If maintenance is performed based on cumulative error counts, then all equipment elements are treated uniformly, but equipment elements with naturally recovered errors or preventive maintenance already performed are incorrectly flagged for service
Solution Approach 1:
The system incorporates feedback mechanisms by continuously monitoring error rates and comparing them against dynamic thresholds. The maintenance determination unit receives real-time feedback from error rate calculations and adjusts maintenance recommendations accordingly, preventing false positives for equipment that has recovered or is already being maintained
Solution Approach 2:
The patent performs preliminary error rate analysis and trend detection before triggering maintenance alerts. By calculating error rates over time windows and identifying sustained degradation patterns before they reach critical thresholds, the system can take preliminary actions to prevent unnecessary maintenance while still catching genuine issues
Data Source
AI summary
There is provided an equipment element maintenance analysis system including: a history information acquirer that is attached with at least one equipment element and acquires, at a predetermined timing, operation history information on a piece of manufacturing equipment for manufacturing a product; an error rate calculator that calculates an error rate based on the number of errors related to each of the at least one equipment element, included in the operation history information; a maintenance determiner that determines maintenance necessity of each of the at least one equipment element; and a notifier that notifies an information item on an equipment element determined to require maintenance among the at least one equipment. The error rate calculator calculates, as a latest error rate, an error rate in a latest predetermined period from the acquired operation history information, the maintenance determiner determines an equipment element with the latest error rate greater than or equal to a predetermined value among one or more equipment elements with a large number of errors as the equipment element that requires maintenance, the one or more equipment elements being included in the at least one equipment element, and the notifier lists the information on the equipment elements with a large number of errors in order, and notifies the number of errors and requirement of maintenance.