JP7632229B2 - Maintenance management system and method for returnable items - Google Patents

Description

The present invention relates to a maintenance management system and a maintenance management method for returnable items.

For example, beer barrels and carbon dioxide gas cylinders are returnable items that are used repeatedly. To ensure the normal use of returnable items, it is necessary to perform regular maintenance on collected returnable items. There are multiple maintenance items for returnable item maintenance, and the time required for each maintenance item varies. For this reason, in the past, in order to achieve efficient maintenance operations, collected returnable items were stored, and when a certain amount of inventory had accumulated, the status of each returnable item was checked and an operation was decided based on the status. However, the conventional method had the problem that a large space had to be prepared to store returnable items that were waiting for status confirmation after being received.

The following Patent Documents 1 to 3 are examples of prior art documents that show the state of the art in the technical field related to the present invention.

JP 2002-154547 A JP 2004-280676 A JP 2011-258145 A

The present invention has been made to solve the above problems, and aims to provide a maintenance management system and method for returnable items that can reduce the number of returnable items waiting for status confirmation after being stored and perform maintenance efficiently.

The returnable item maintenance management system of the present invention includes a storage device that stores inventory management data and a maintenance work master, and a processor that executes the first to fourth processes.

The inventory management data stored in the storage device is data that links the individual numbers assigned to each returnable item with the scheduled maintenance times for each maintenance item for the returnable item. The maintenance work master is data that links the maintenance items for returnable items with the standard maintenance times.

The first process executed by the processor is a process of acquiring the individual number of the target returnable item. The second process is a process of checking the acquired individual number against the inventory management data to determine whether any of the maintenance items for the target returnable item have a scheduled maintenance date. The third process is a process of acquiring a standard maintenance time from the maintenance work master for the maintenance items for which a scheduled maintenance date has arrived, and determining whether maintenance of the target returnable item is possible during the first scheduled period based on the acquired standard maintenance time. The fourth process is a process of issuing a maintenance instruction to perform maintenance on the target returnable item if maintenance is possible during the first scheduled period, and issuing a temporary storage instruction to temporarily store the target returnable item if maintenance during the first scheduled period is difficult.

The returnable item maintenance management method according to the present invention involves preparing inventory management data and a maintenance work master in advance as a preparation stage, and then executing the following first to fourth steps.

In the first step, the individual number of the target returnable item is obtained. In the second step, the obtained individual number is compared with inventory management data to determine whether any of the maintenance items for the target returnable item have a scheduled maintenance date. In the third step, for the maintenance items for which a scheduled maintenance date has arrived, the standard maintenance time is obtained from the maintenance work master, and based on the obtained standard maintenance time, it is determined whether maintenance of the target returnable item is possible during the first scheduled period. Then, in the fourth step, if maintenance during the first scheduled period is possible, a maintenance instruction is issued to perform maintenance on the target returnable item, and if maintenance during the first scheduled period is difficult, a temporary storage instruction is issued to temporarily store the target returnable item.

According to the turnable item maintenance management system and maintenance management method of the present invention, a decision is made in real time as to whether the target returnable item should be maintained during the first scheduled period or temporarily stored. This makes it possible to reduce the inventory of returnable items waiting for confirmation of their status after they are stored.

1 is a block diagram showing a configuration of a maintenance management system according to an embodiment of the present invention. FIG. 2 is a data correlation diagram in the maintenance management system shown in FIG. 1 . 2 is a diagram specifically illustrating a process performed by a worker in the maintenance management system shown in FIG. 1 . 2 is a flowchart showing the flow of maintenance processing in the maintenance management system shown in FIG. 1. 2 is a flowchart showing the flow of maintenance processing in the maintenance management system shown in FIG. 1. 2 is a flowchart showing the flow of maintenance processing in the maintenance management system shown in FIG. 1. 4 is a flowchart showing a flow of a process for updating the worker master data in the maintenance management system shown in FIG. 1 .

Below, an embodiment of the present invention will be described with reference to the drawings. However, when the numbers, quantities, amounts, ranges, etc. of each element are mentioned in the embodiments shown below, the invention is not limited to the mentioned numbers unless specifically stated or clearly specified in principle. Furthermore, the structures, steps, etc. described in the embodiments shown below are not necessarily essential to the invention unless specifically stated or clearly specified in principle.

Figure 1 is a block diagram showing the configuration of a maintenance management system for returnable items according to an embodiment of the present invention. Returnable items 10 that are the subject of maintenance management in this maintenance management system are, for example, barrels of beer, carbon dioxide gas cylinders, and linen products such as work clothes and sheets. This maintenance management system includes an inventory management computer 2 and a work site terminal 4.

The inventory management computer 2 is a computer having a storage device and a processor (not shown). The storage device of the inventory management computer 2 stores returnable item inventory management data D1, maintenance work master D2, worker master D3, worker skill master D4, and start/end time master D5. The processor of the inventory management computer 2 executes processes P2 to P4 and P7 to P11, which will be described later.

The work site terminal 4 is a wireless mobile terminal that can be wirelessly connected to the work site terminal 4 via a wireless router 6 that is wired to the inventory management computer 2. The work site terminal 4 has a display that displays information sent from the inventory management computer 2, and input keys that allow workers to input information. The work site terminal 4 also has a scanner that reads one-dimensional and two-dimensional codes attached to returnable items 10.

Here, we will explain the correlation of data in this maintenance management system, including data D1 to D5 stored in the inventory management computer 2, using the data correlation diagram shown in Figure 2.

The returnable item inventory management data D1 includes a serial number, an address, and a status. The serial number is a unique individual number assigned to each returnable item 10. Each serial number is associated with an address and a status. The address is information indicating the location where the returnable item 10 is currently located among incoming inventory, maintenance inventory, outgoing inventory, and disposal. The status is a status related to the maintenance of the returnable item 10, and includes the planned maintenance date and its allowable error days, the planned disposal date and its allowable error days, the date of entry (the date when the serial number is read during the work at the time of entry described below, also referred to as the "scan date"), the date of maintenance completion, the date of exit, etc. In addition, when maintenance of multiple items (maintenance A, B, and C in the example of FIG. 2) is performed, the planned maintenance date is registered for each maintenance item.

A maintenance item is the content of the maintenance. For example, if the returnable item 10 is a carbon dioxide gas cylinder, the maintenance items registered are inspection items such as air leak checks and statutory inspections, and part replacement items such as periodic replacement of valve O-rings and replacement of the valve body. In addition, for maintenance items that are performed periodically, the maintenance cycle is also registered, for example, every 1 year, 3 years, 5 years, or 8 years.

The maintenance work master D2 contains maintenance items and standard maintenance times, which are associated with each other. Standard maintenance time is the standard time required for maintenance work. Since the time required differs depending on the content of the maintenance, standard maintenance times are registered for each maintenance item. For example, maintenance A is registered as 10 minutes, maintenance B as 15 minutes, and maintenance C as 30 minutes.

The worker master D3 includes a worker number, a worker skill rank, and a worker-specific item, standard work time. The worker number is a unique personal number assigned to each worker. Each worker number is associated with a worker skill rank and a worker-specific item, standard work time. The worker skill rank is the skill rank of the maintenance work of the worker identified by the worker number. Either high, medium, or low skill rank is registered for each maintenance item. The worker-specific item, standard work time, is the standard work time required for a certain maintenance work by a worker identified by the worker number. The worker-specific item, standard work time, is registered for each worker number and for each maintenance item.

The worker skill master D4 includes work skill ranks and work times by work skill rank. Work skill ranks are set for each maintenance item, and work times by work skill rank are associated with the work skill rank for each maintenance item. Work times by work skill rank indicate the range of work times allowed for the associated skill rank. For example, for maintenance A, it is registered that high rank is less than 100 seconds, medium rank is between 100 and 180 seconds, and low rank is 180 seconds or more.

The work start/finish time master D5 includes the work start and finish times of workers. If there are multiple employment types for workers, such as full-time employees, part-timers, and casual employees, the work start and finish times are registered for each employment type.

Meanwhile, the serial number of the returnable item 10 is registered in the one-dimensional or two-dimensional code attached to the returnable item 10. By comparing the serial number and the date of entry (scanning date) of the returnable item 10 with the status in the returnable item inventory management data D1, the target status data d1 is obtained. The target status data d1 includes information on whether the returnable item 10 can be discarded or not, whether maintenance can be performed for each maintenance item, and information on temporary storage.

Target status instruction data d2 is created from the target status data d1. The target status instruction data d2 is data including instructions to the worker, and is transmitted to the work site terminal 4. The target status instruction data d2 includes instructions to the target worker to discard or temporarily store the returnable item 10, or instructions on which maintenance item to perform.

Work performance data d3 is created for each specified period (for example, one day, one week, or one month) from the target status instruction data d2. The work performance data d3 includes planned work schedule data for each worker linked to the time and work item within the scheduled work setting period within the specified period, and actual work time for each worker item. The actual work time for each worker item is the actual work time for each worker and each maintenance item. The work performance data d3 is used to update the worker skill rank for each worker and the standard work time for each worker item in the worker master D3. Furthermore, the planned work schedule data for each worker is used to assign work.

Returning to Figure 1, we will now explain the processing performed by this maintenance management system.

When a returnable item 10 is received, worker A inputs the serial number of the returnable item 10 into the work site terminal 4 (process P1). Process 1 is a process for acquiring the serial number of the received returnable item 10. Hereinafter, the received returnable item 10 is referred to as the target returnable item 10. As described above, the input is performed automatically by reading the one-dimensional code or two-dimensional code attached to the target returnable item 10 with the scanner of the work site terminal 4. If the code is soiled and cannot be read, the serial number can be manually input by operating the input keys. It may also be a device that can read it automatically instead of worker A.

The serial number of the target returnable item 10 entered into the work site terminal 4 is sent to the inventory management computer 2 by a communication means such as wireless communication. The inventory management computer 2 compares the serial number of the target returnable item 10 with the returnable item inventory management data D1 (process P2). Process P2 is a process for determining whether or not there is any maintenance item for which the scheduled maintenance date has arrived among the maintenance items for the target returnable item 10. This process results in the target status data d1 being obtained.

Next, the inventory management computer 2 obtains the standard maintenance time from the maintenance work master D2 for the maintenance items for which the scheduled maintenance time specified by the target status data d1 has arrived. The inventory management computer 2 also obtains the required work time for each worker from the worker master D3, and calculates the total maintenance work time for each worker based on the required work time for each worker obtained. Then, the inventory management computer 2 determines whether it is possible to maintain the target returnable item 10 during the first scheduled period based on the total maintenance work time for each worker and the standard maintenance time for the maintenance items for which maintenance is scheduled. In detail, it determines whether there is a worker who can maintain the target returnable item 10 during the first scheduled period. Based on the result of this determination, the inventory management computer 2 determines what instructions to give to which worker. Then, it creates and updates the work schedule data for each worker (process P3). For example, the first scheduled period is the working period on the day the serial number of the returnable item 10 is read.

Next, the inventory management computer 2 transmits worker-specific work schedule data, including the instructions determined in process P3, to the work site terminal 4. In particular, if there is a worker who can perform maintenance on the target returnable item 10 during the first planned period, a maintenance instruction is transmitted to that worker. If maintenance during the first planned period is difficult, worker-specific work schedule data, including a temporary storage instruction, is transmitted to the same worker or another worker to temporarily store the target returnable item 10. In addition, if it is time to discard the target returnable item 10, worker-specific work schedule data, including a disposal instruction, is transmitted to the same worker or another worker to discard the target returnable item 10 (process P4).

The work site terminal 4 displays the work schedule and work instructions for the worker on the display based on the work schedule data for each worker sent from the inventory management computer 2 (process P5). The work site terminal 4 that displays the work display is limited to the work site terminal 4 of worker B. Worker B is the worker selected as the person in charge of the work on the target returnable item 10. Therefore, worker B may be the same person as worker A who performed process P1, or may be a different person.

Worker B follows the work instructions displayed on the display of the work site terminal 4 and transports the target returnable item 10 to a maintenance area, a temporary storage area, or a disposal area. If the target returnable item 10 is a maintenance target, worker B performs the maintenance in accordance with the work instructions.

After completing the maintenance work, worker B inputs the work results into the work site terminal 4 and transmits them to the inventory management computer 2 (process P6).

The inventory management computer 2 collects the work time for each worker from the work results sent from the work site terminal 4 (process P7). Then, the collected work time for each worker is registered in the work results data d3 (process P8).

After a specified period of time has elapsed, the inventory management computer 2 calculates the average work time for each worker and each maintenance item from the work performance data d3 (process P9). Next, the inventory management computer 2 calculates a work time correction, which is a correction to the worker-specific item standard work time, based on the difference between the currently calculated average work time and the worker-specific item standard work time registered in the worker master D3 (process P10). The inventory management computer 2 then corrects the worker-specific item standard work time registered in the worker master D3 based on the work time correction (process P11).

The above describes the processing performed by this maintenance management system. Below, we will explain in more detail the processing performed by the worker using Figure 3.

First, the code of the target returnable item 10 is scanned by the work site terminal 4 (process P101). The serial number of the target returnable item 10 obtained by scanning is compared with the turnable item inventory management data D1 together with the scan date (process P102). An example of the configuration of status data is shown in the turnable item inventory management data D1 in FIG. 3. The manufacturing date, planned disposal date, planned maintenance A date, planned maintenance B date, planned maintenance C date, disposal date, scan date, maintenance completion date, and shipping date are associated with the serial number. In the example shown in FIG. 3, the scan date of the returnable item with serial number Ns2 is March 31, 2020, while the planned date of maintenance A is January 1, 2019, so the planned date of maintenance A has already passed. In this case, the inventory management computer 2 determines whether there is time for maintenance work (process P103) and issues instructions to a worker who can perform maintenance (process P104).

The contents displayed on the display of the work site terminal 4 differ depending on whether or not there is maintenance work time. Display W0 shown in FIG. 3 is a work schedule screen for a worker (employee B). When the work terminal is started up, it requests the worker to enter an identification number (e.g., employee number) to identify the individual. When the identification number is entered, the work schedule for that worker is displayed based on the worker-specific work schedule data sent from the inventory management computer 2. The work schedule is the work schedule for the relevant day (e.g., the day the identification number was entered). The work schedule displays the work number, the scheduled work time, and the serial number and work name of the target returnable item 10 in order of the scheduled work time. For example, when a work number is selected on display W0, or when the scheduled time arrives, the screen transitions to a screen that indicates the details of the work, such as display W1 or display W2.

Display W1 shown in FIG. 3 is an example of a display when there is work time for maintenance A. Display W1 instructs the worker to perform maintenance A on the returnable item with serial number 2. In addition, the scheduled start time and standard time for maintenance A are displayed as reference information for maintenance A. On the other hand, display W2 shown in FIG. 3 is an example of a display when there is no work time for maintenance A. Display W2 indicates that the maintenance work time has already been exceeded, and instructs "temporary placement" as the work. When the worker selects "Start/Complete" on display W1 or display W2 before starting the work, timing of the work time for that work begins, and when the work is finished, the worker selects "Start/Complete" again to complete the timing of the work time.

If there is time available for maintenance A, display W1 instructs the worker to perform maintenance on the target returnable item 10 (process P105). If there is no time available for maintenance A, display W2 instructs the worker to temporarily place the target returnable item 10 (process P106). The temporarily placed target returnable item 10 is subjected to maintenance processing at another time (e.g. the next day) (process P107). The target returnable item 10 for which maintenance has been completed is stored in the regular inventory area for release (process P108).

After the maintenance is completed, the status of the target returnable item 10 registered in the turnable item inventory management data D1 is updated. In the example shown in FIG. 3, if maintenance A was performed this time, the scheduled date of maintenance A is updated. If the cycle of maintenance A is three years, March 31, 2023, three years after the first scheduled period (March 31, 2020), is registered as the scheduled date of the next maintenance A.

In addition, in the turnable item inventory management data D1, in addition to the scheduled date for each maintenance item, the allowable error period is also registered. Therefore, even if the scan date is before the scheduled maintenance date, maintenance can be performed as long as it is within the range of the allowable error period. The allowable error period is set to a longer period for items that take a longer time to be stocked after being sent out. Furthermore, for maintenance items that must be performed by a deadline, such as legal inspections, and important items that are not required, a longer allowable error period is set than for other items so that maintenance can be performed before the scheduled date.

Finally, the process flow of this maintenance management system will be explained using Figures 4 and 5.

Figures 4 to 6 show the flow of maintenance processing by this maintenance management system in the form of a flowchart. Figure 4 shows the main flowchart of the maintenance processing in this management system. Figure 5 shows a flowchart for generating target status data d1 for new returnable items 10 in this management system and updating returnable item inventory management data D1. Figure 6 shows a flowchart for the operator terminal 4 in this management system.

First, the main flow chart of FIG. 4 will be described. In step S002, it is determined whether or not a new returnable item 10 is present. If a new returnable item 10 is present, the process proceeds to step S004, and after processing in step S004, the process proceeds to step S600. In step S004, a serial number reading process is performed, target status data d1 for the new returnable item 10 is generated, and the returnable item inventory management data D1 is updated. After updating, the process proceeds to step S006. If no new returnable item 10 is present, the process proceeds from step S002 to step S006.

Details of the serial number reading process in step S004 are shown in the flowchart of Figure 5. If there is a new returnable item 10, the worker opens the maintenance management screen on the work site terminal 4 and inputs his worker number (step S101). The worker selects the inventory screen on the work site terminal 4 (step S102) and inputs the serial number of the target returnable item 10 (step S103). The serial number can be input by reading it with the scanner of the work site terminal 4, or by manually inputting it using the input keys.

The inventory management computer 2 searches the returnable item inventory management data D1 based on the input serial number (step S104) and checks the status of the target returnable item 10 (step S105).

Based on the result of checking the status of the target returnable item 10, the inventory management computer 2 determines whether the scheduled disposal date has arrived (step S106). If the scheduled disposal date has arrived, the inventory management computer 2 changes the status from "discarded" to "possible" (step S107).

Based on the results of checking the status of the target returnable item 10, the inventory management computer 2 determines whether the scheduled date for maintenance A has arrived (step S108). If the scheduled date for maintenance A has arrived, the inventory management computer 2 changes the status from "Maintenance A" to "Possible" (step S109) and obtains the standard maintenance time for maintenance A from the maintenance work master D2.

Based on the results of checking the status of the target returnable item 10, the inventory management computer 2 determines whether the scheduled date for maintenance B has arrived (step S110). If the scheduled date for maintenance B has arrived, the inventory management computer 2 changes the status from "Maintenance B" to "Possible" (step S111) and obtains the standard maintenance time for maintenance B from the maintenance work master D2.

Furthermore, based on the results of checking the status of the target returnable item 10, the inventory management computer 2 determines whether the scheduled date for maintenance C has arrived (step S112). If the scheduled date for maintenance C has arrived, the inventory management computer 2 changes the status of "Maintenance C" to "Possible" (step S113) and obtains the standard maintenance time for maintenance C from the maintenance work master D2.

Next, the inventory management computer 2 updates the returnable item inventory management data D1 with the status data d1 of the target returnable item 10 created in the above procedure (step S114). This ends the serial number reading process.

Returning to the flowchart of Fig. 4, the explanation will be continued. The processes from step S006 to step S016 are process steps for causing the inventory management computer 2 to process the temporarily stored and newly received unprocessed returnable items in the following order of priority:
Priority 1: Discard processing Priority 2: Those whose scheduled maintenance date is shorter than the second hour (those with less time until the maintenance period)
Priority 3: Items with a temporary storage period longer than the third hour (items with a long retention period)
Priority 4: Items with a short time until disposal

In step S006, the inventory management computer 2 reads the returnable item inventory management data D1 for returnable items that have been stored, including those temporarily stored, and have not been discarded or shipped, in order to select returnable items that require maintenance.

In step S008, it is determined whether the "discard" status of the returnable item 10 is possible. If the "discard" status is "possible" (YES), the process proceeds to step S018. If the "discard" status is not "possible" (NO), the process proceeds to step S012.

In step S012, it is determined whether the difference between the scheduled maintenance date of any of the returnable items 10 and the current date is shorter than the second time TD2. If it is shorter than the second time TD2 (YES), proceed to step S018. If not (NO), proceed to step S014.

In step S014, it is determined whether the difference between the current date and the date of receipt of the returnable item 10 is greater than the third time. If it is greater than the third time (YES), proceed to step S018. If it is not (NO), proceed to step S016.

In step S016, of the remaining returnable items 10, the one with the shortest number of days (period) until the planned disposal date is selected as the returnable item 10.

By ranking tasks in the above manner, it is possible to reduce inventory space, shorten the retention (temporary storage) period, and increase the turnover rate of returnable items 10.

In step S018, the inventory management computer 2 determines whether maintenance of the returnable item can be completed by the end of work hours for all workers based on the worker-specific schedules, i.e., whether changes or additions can be made to the worker-specific work schedule data. For example, the worker with the earliest free time in the worker-specific schedule is selected based on the current time. Then, for the maintenance items for which maintenance of the returnable item 10 is possible, the total maintenance standard work time is calculated based on the worker-specific item-specific standard work time obtained from the worker master D3. Then, it is determined whether the aforementioned total maintenance standard work time can be completed by the scheduled end time of the last task in the worker's current work schedule when it is added.

If it is possible to finish by the scheduled end of the shift, proceed to step S020. If not, select the worker with the second-earliest free time in the worker-specific schedule from the current time, and use the same procedure to determine whether that worker can finish by the scheduled end of the shift. If it is possible to finish by the scheduled end of the shift, proceed to step S020. If multiple workers have free time at the same time, priority may be given to workers with higher skill ranks, as described below. If it is not possible to complete by the scheduled start of the shift for all employees, proceed to step S022.

In step S020, the inventory management computer 2 adds maintenance work (including disposal work) for the returnable item 10 to the free time closest to the current time in the worker-specific work schedule data for that worker, and issues instructions for that returnable item by sending the new worker-specific work schedule data to the other industry site terminal 4. Then, the process proceeds to step S026.

If there is insufficient work time to perform maintenance on the returnable item 10, temporary storage work will be instructed. Step S022 is a step for determining whether the temporarily stored item is a newly stored item. If the temporarily stored item is a newly stored item, the process proceeds to step S024, and if it is not a newly stored item, the item has already been temporarily stored and so the process proceeds directly to step S026.

In step S024, the inventory management computer 2 selects the worker who has free time in his/her worker schedule from the current time based on the worker-specific schedule. It adds the temporary placement of the returnable item 10 to the free time closest to the current time in the worker-specific work schedule data of that worker, and issues a temporary placement instruction for the returnable item by sending the new worker-specific work schedule data to the work site terminal 4. Then it proceeds to step S026.

In step S026, the inventory management computer 2 determines whether the current time is before the end of work hours for all workers. If it is before the end of work hours, the process returns to step S002; if not, the process ends.

Next, the process centered on the work site terminal 4 will be described using the flowchart in Figure 6. First, in step S152, the worker opens the maintenance management screen on the work site terminal 4 and inputs the worker number. Next, the worker selects the work schedule screen (corresponding to display W0 in Figure 2) on the work site terminal 4 to confirm the work. Then, the first work number is selected. The process then moves to step S0154.

In step S0154, the work site terminal 4 displays the work instruction screen, showing the serial number of the target item and the work content (corresponding to displays W1 and W2 in Figure 2).

In step S0156, when the worker selects "Start/Complete" on the work site terminal 4, the work site terminal starts timing the work time for that task and at the same time notifies the inventory management computer 2 of the start of that task for that item.

In step S158, the worker performs the work and the work site terminal 4 times the work. When the worker finishes the work, he or she again selects "Start/Complete" on the work site terminal 4.

In step S160, the work site terminal 4 transitions to work completion processing, stops timing the work, and transmits the completion of the work and the time clocked as the actual work time of the work by the worker to the inventory management computer 2.

In step S162, the inventory management computer 2 registers the actual work time received from the field work terminal 4 as the actual work time by worker item in the work performance data d3. The inventory management computer 2 updates the item for which work has been completed in the target status data d1, and updates the relevant portion of the returnable item inventory management data (e.g., the scheduled maintenance date).

Next, in step S164, the work site terminal 4 determines whether all scheduled work has been completed, and if not, returns to step S154 and displays an instruction screen for the next work. If all scheduled work has been completed, the process proceeds to step S166. In step S166, the completion of scheduled work is displayed.

Figure 7 shows a flow chart of the process of updating the worker master data by this maintenance management system. The process shown in this flowchart is executed following execution of step S162 in the flowchart of Figure 6.

Steps S201 to S203 are processes for generating work performance data d3. In step S201, the inventory management computer 2 collects the actual work time for each worker item, and in steps S202 and S203, calculates the average actual work time for each worker item.

Specifically, in step S201, the actual work time for each worker for the most recent fixed time (e.g., 10 times) for the item for which maintenance was performed is prepared. In step S202, outliers are removed from the actual work time for each worker for the most recent fixed time prepared in step S201. An outlier is defined as, for example, a value that deviates from the standard time by a predetermined percentage or more. Alternatively, it may be a value that deviates from the median by a predetermined percentage or more. In step S203, the average work time for the item for which maintenance was performed is calculated using the set of past work times from which the outliers have been removed.

Steps S204 to S211 are processes for updating the worker master D3. The inventory management computer 2 determines whether the average work time calculated in step S203 has been shortened relative to the current worker-specific standard work time registered in the worker master D3 (step S204). If the average work time is shorter than the current worker-specific standard work time, the inventory management computer 2 makes a negative correction to the worker-specific standard work time in the worker master D3 (step S205). Conversely, if the average work time is not shorter than the current worker-specific standard work time, the inventory management computer 2 makes a positive correction to the worker-specific standard work time in the worker master D3 (step S206). However, if the difference between the average work time and the current worker-specific standard work time is within a predetermined error range, the worker-specific standard work time is not corrected.

A specific example of the correction of the worker master D3 will be given below. In step S201, the most recent six past work times for maintenance B are prepared, and their values are assumed to be 11 minutes, 5 minutes, 9 minutes, 13 minutes, 11 minutes, and 11 minutes. If the standard time for maintenance B is 10 minutes and an abnormal value is +-30% or more, then in step S202, 5 minutes and 13 minutes are excluded as abnormal values. Then, in step S203, the average time of the remaining 11 minutes, 9 minutes, 11 minutes, and 11 minutes, 10.5 minutes, is calculated.

If the worker-specific standard work time for maintenance B registered in the worker master D3 is 11 minutes, in step S204, it is determined that the average time has been shortened from the current worker-specific standard work time. In this case, in step S205, the worker-specific standard work time in the worker master D3 is negatively corrected. For example, the difference of 0.5 minutes between the current worker-specific standard work time of 11 minutes and the average time of 10.5 minutes may be calculated, and the time obtained by multiplying this difference of 0.5 minutes by a correction coefficient of 1 or less may be used as the correction time for the negative correction. Specifically, if the correction coefficient is 0.6, the correction time is 0.3 minutes, so the time 10.7 minutes obtained by subtracting the correction time 0.3 minutes from the worker-specific standard work time of 11 minutes is registered as the new worker-specific standard work time for maintenance B.

Next, the inventory management computer 2 determines whether there is a difference between the standard work time for each worker in the worker master D3 and the work time for each work skill rank in the worker master D4 (step S207). The worker master D3 registers the worker skill rank for each worker. The worker skill rank corresponds to the work skill rank in the worker skill master D4, and the work time for each work skill rank is set for the work skill rank. For example, assume that the worker's current worker skill rank for maintenance B is "low" and the work time for the corresponding work skill rank is 11 minutes or more. If the standard work time for each worker for maintenance B registered in the worker master D3 is updated to 10.7 minutes, a difference will have occurred between the work time for each work skill rank.

If there is a difference between the standard work time for each worker in the worker master D3 and the work time for each skill rank, the inventory management computer 2 calculates the worker skill rank from the standard work time for each worker in the worker master D3 (step S208). In the above example, the worker skill rank for maintenance B calculated from the standard work time for each worker of 10.7 minutes is "medium."

The inventory management computer 2 determines whether the worker skill rank calculated in step S208 is different from the current worker skill rank for the three most recent times (step S209). In the above example, it determines whether the worker skill rank was "medium" for the three most recent times.

If the three most recent past worker skill ranks differ from the current worker skill rank, the inventory management computer 2 changes the worker skill rank in the worker master D3. In the above example, the worker skill rank of maintenance B registered in the worker master D3 is changed from "low" to "medium." In addition, the inventory management computer 2 changes the worker-specific standard work time registered in the worker master D3 to match the work time by work skill rank of the work skill rank registered in the worker skill master D4 (step S210).

Finally, if the worker-specific standard work time is corrected in step S206, the inventory management computer 2 updates the worker master D3 using the correction or change results. Also, if the work skill rank and worker-specific standard work time are changed in step S210, the inventory management computer 2 updates the worker master D3 using the change results (step S211). In this way, the inventory management computer 2 performs the calculation of step S162 in the flowchart of FIG. 6.

2 Inventory management computer 4 Work site terminal 10 Returnable items D1 Returnable item inventory management data D2 Maintenance work master D3 Worker master D4 Worker skill master D5 Start/end time master d1 Object status data d2 Object status instruction data d3 Work performance data

Claims (6)

A returnable item maintenance management system, comprising:
A storage device;
A processor,
The storage device includes:
Inventory management data linking individual numbers assigned to each of the returnable items with scheduled maintenance times for each maintenance item of the returnable items;
A maintenance work master in which the maintenance items of the returnable products are linked to standard maintenance times is stored;
The processor,
A first process of acquiring an individual number of a target returnable item;
A second process of collating the acquired individual number with the inventory management data to determine whether or not there is any maintenance item for which a maintenance scheduled time has arrived among the maintenance items for the target returnable item;
a third process of acquiring a standard maintenance time from the maintenance work master for the maintenance item for which the scheduled maintenance time has arrived, and determining whether or not the maintenance of the target returnable product during the first scheduled period is possible based on the acquired standard maintenance time;
A returnable item maintenance management system characterized by executing a fourth process of issuing a maintenance instruction to maintain the target returnable item if maintenance is possible during the first scheduled period, and issuing a temporary storage instruction to temporarily store the target returnable item if maintenance during the first scheduled period is difficult. The storage device further stores a worker master in which a required work time for each maintenance item is registered for each worker,
The processor,
In the third process, a total maintenance work time is calculated for each worker based on the required work time for each worker acquired from the worker master, and based on the total maintenance work time for each worker and the acquired standard maintenance time, it is determined whether there is a worker who can maintain the target returnable item during the first scheduled period;
The returnable item maintenance management system according to claim 1, characterized in that in the fourth process, the maintenance instruction is issued to a worker who is able to perform maintenance on the target returnable item during the first planned period. 3. The returnable item maintenance management system according to claim 2, wherein the processor executes a fifth process of correcting the work time of each worker registered in the worker master based on the actual work time of the worker. A maintenance management system for returnable items as described in any one of claims 1 to 3, characterized in that the processor executes a sixth process of automatically registering the next scheduled maintenance date for a maintenance item for which maintenance has been performed in the inventory management data. A method for maintaining and managing returnable items, comprising:
inventory management data in which individual numbers assigned to the respective returnable items are linked to scheduled maintenance times for each maintenance item of the returnable items;
A maintenance work master in which the maintenance items of the returnable products are linked to standard maintenance times is prepared in advance in a computer ;
Obtain the individual number of the returnable item in question,
By comparing the acquired individual number with the inventory management data, it is determined whether or not there is any maintenance item for which a maintenance scheduled time has arrived among the maintenance items for the target returnable item;
For the maintenance item for which the scheduled maintenance time has arrived, a standard maintenance time is acquired from the maintenance work master, and based on the acquired standard maintenance time, it is determined whether or not maintenance of the target returnable item during a first scheduled period is possible;
A method for managing maintenance of returnable items, characterized in that the computer is caused to issue a maintenance instruction to maintain the target returnable item if maintenance during the first scheduled period is possible, and to issue a temporary storage instruction to temporarily store the target returnable item if maintenance during the first scheduled period is difficult. A worker master in which the required work time for each maintenance item is registered for each worker is prepared in advance in the computer ;
calculating a total maintenance work time for each worker based on the required work time for each worker acquired from the worker master, and determining whether there is a worker who can maintain the target returnable item during the first scheduled period based on the total maintenance work time for each worker and the acquired standard maintenance time, thereby determining whether maintenance of the target returnable item during the first scheduled period is possible;
The method for maintenance management of returnable items described in claim 5, characterized in that the computer is caused to issue the maintenance instruction to a worker who can maintain the target returnable item during the first scheduled period.

Images