Worker Action Monitoring for Early Maintenance Error Detection
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Solution Overview
Problem
Existing systems fail to support workers effectively when they perform erroneous work or are unfamiliar with maintenance tasks before an error code is output, leading to inefficiencies and reduced work quality.
Innovation Solution
An abnormal state monitoring system that includes a sensor information acquisition unit, work check data holding unit, and abnormality detection unit to detect abnormalities in work by comparing sensor information with predefined work check data, enabling early intervention and support for workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If remote support is provided only after error code output, then system complexity is reduced, but work efficiency and quality deteriorate due to delayed intervention
Solution Approach 1:
The system performs preliminary actions by continuously monitoring worker actions against the work procedure before errors occur. Sensors detect worker actions in real-time and compare them with predetermined work procedures, enabling early detection of deviations before they result in error codes. This preliminary monitoring and comparison mechanism allows intervention to occur proactively rather than reactively after errors manifest.
2Reliability
If continuous monitoring of worker actions is implemented, then work quality improves through early abnormality detection, but device complexity increases due to additional sensors and processing units
Solution Approach 1:
The monitoring system is segmented into distinct functional modules: sensor units for detecting specific worker actions, a work procedure storage unit containing predetermined procedures, and a comparison unit for analyzing deviations. This segmentation allows each component to perform a specific function, making the overall system more manageable and less complex while maintaining comprehensive monitoring capability across multiple work steps.
Solution Approach 2:
The system enables self-service monitoring where the worker's own actions are automatically detected by sensors and compared against the work procedure without requiring external supervision. The comparison unit automatically identifies deviations and can provide feedback to the worker, reducing the need for complex external monitoring infrastructure while maintaining high work quality through continuous self-monitoring.
3Measurement precision
If real-time comparison of sensor information with work procedures is performed, then abnormality detection precision improves, but information processing time increases
Solution Approach 1:
The comparison unit performs partial comparison by focusing only on critical action elements that are most likely to deviate from the work procedure, rather than analyzing every single worker movement. The system identifies and monitors key checkpoints in the work procedure where deviations are most significant, enabling high detection precision for critical errors while reducing overall processing time by excluding less important actions from continuous monitoring.
Data Source
AI summary
Work efficiency and quality are improved. The invention includes: a sensor information acquisition unit configured to acquire, from a sensor configured to detect a state of a worker, sensor information indicating a detection result; a work check data holding unit configured to hold in advance, as work check data, an action of the worker assumed from a work procedure; and an abnormality detection unit configured to detect an abnormality in work by comparing the sensor information with the work check data. Further, a control unit is provided that is configured to generate flag data including a flag indicating an abnormal level and state information indicating an abnormal state when the abnormality detection unit detects an abnormality, and transmit the flag data to the management device. A management device transmits instruction information based on the flag data.