JP7820327B2 - System for improving the operation of production facilities, method for improving the operation of production facilities, and program for improving the operation of production facilities - Google Patents

Description

This disclosure relates to a system for improving the operation of production facilities, and more particularly to a system that uses sensor data.

In recent years, IoT (Internet of Things) technology has been used to manage production equipment in factories and other facilities. IoT devices attached to each piece of equipment send information to a server. The server can detect the operating status and abnormalities of the production equipment based on the information obtained from each IoT device.

Regarding IoT technology, for example, Japanese Patent Application Laid-Open Publication No. 2019-087090 (Patent Document 1) discloses a production management system. This production management system includes "a production management device having multiple notification devices that notify operation information of production equipment, an information generation unit that generates the operation information, a transmission unit, and a control unit. The notification devices are classified according to at least one of the role of the notification device's user in the production line, the location where the user performs work, and the location where the notification device is used. The control unit determines the notification device to be the transmission target based on the operation status indicated by the operation information and/or the production equipment whose operation status is indicated, and the classification, and the transmission unit transmits the operation information only to the transmission targets" (see [Abstract]).

Further information on IoT technology is disclosed in Patent Documents 2 and 3.

JP 2019-087090 A Japanese Patent Application Laid-Open No. 2020-126533 Japanese Patent Application Laid-Open No. 2021-056927

The technologies disclosed in Patent Documents 1 to 3 may be able to manage production processes and detect the presence or absence of equipment anomalies. However, they cannot provide users with the information necessary to improve the operation of production equipment. Support for improving the operation of production equipment is particularly important for small and medium-sized businesses that do not have the know-how to implement digital transformation (DX) and automate their operations. Therefore, there is a need for technology that can provide users with the information necessary to improve the operation of production equipment.

This disclosure has been made in light of the above-mentioned background, and its purpose in one aspect is to provide technology for presenting users with information necessary for improving the operation of production equipment.

According to one embodiment, a system for improving operations at production facilities is provided. The system includes an acquisition unit that acquires signals from sensor devices installed in the production facilities and user input; an analysis unit that analyzes the signals or the signals and document input to obtain information related to the production efficiency of the production facilities; and a display unit that displays information related to the production facilities. The display unit outputs information related to the production efficiency of the production facilities to a device of a first user. The acquisition unit acquires, from the first user, improvement information for the production facilities based on the information related to the production efficiency of the production facilities. The display unit outputs the improvement information for the production facilities to a device of a second user.

In one aspect, the first user is a consultant who supports improving the productivity of production facilities, and the second user is an employee of the company that owns the production facilities.

In one aspect, the information regarding the production efficiency of the production equipment includes information regarding the time availability rate of the production equipment. The signal includes first information indicating whether the production equipment is operating. The analysis unit calculates the operating time of the production equipment based on the first information, and calculates the time availability rate based on the load time and operating time of the production equipment.

In one aspect, the information regarding the production efficiency of the production equipment includes information regarding the performance rate of the production equipment. The signal includes second information indicating completion of production of the processed product. The analysis unit calculates the production volume of the processed product per reference cycle time based on the second information, and calculates the performance rate based on the production volume per reference cycle time and the operating time.

In one aspect, the information regarding the production efficiency of the production equipment includes information regarding the yield rate. The signal or report includes third information regarding the processed products and/or defective products. The analysis unit calculates the number of processed products and the number of defective products based on the third information, and calculates the yield rate based on the number of processed products and the number of defective products.

In one aspect, the information regarding the production efficiency of the production equipment includes the overall equipment efficiency of the production equipment. The analysis unit calculates the overall equipment efficiency based on the availability rate, performance rate, and quality rate.

In one aspect, the information regarding the production efficiency of the production equipment includes loss factors of the production equipment. The analysis unit determines the loss factors based on the signal.

According to one aspect, the production equipment improvement information includes historical information of past improvement information entered by the first user.

According to one aspect, the improvement information for the production equipment includes additional information on advice from the first user added to information on the production efficiency of the production equipment.

According to another embodiment, a method for improving operations at a production facility is provided. The method includes the steps of acquiring signals from sensor devices installed in the production facility and user input, analyzing the signals or the signals and document input to obtain information related to the production efficiency of the production facility, displaying the information related to the production efficiency of the production facility on a first user's device, acquiring improvement information for the production facility based on the information related to the production efficiency of the production facility from the first user, and outputting the improvement information for the production facility to a second user's device.

According to another embodiment, a program for improving operations at production facilities is provided. The program causes a computer to execute the following steps: acquiring signals from sensor devices installed in the production facilities and user input; analyzing the signals or the signals and document input to obtain information related to the production efficiency of the production facilities; displaying the information related to the production efficiency of the production facilities on a first user's device; acquiring, from the first user, improvement information for the production facilities based on the information related to the production efficiency of the production facilities; and outputting the improvement information for the production facilities to a second user's device.

In accordance with one embodiment, it is possible to provide users with the information necessary to improve the operation of production equipment.

These and other objects, features, aspects and advantages of the present disclosure will become apparent from the following detailed description of the disclosure taken in conjunction with the accompanying drawings.

1 is a diagram showing an example of a configuration of a system 10 according to the present embodiment. FIG. 2 is a diagram illustrating an example of a functional configuration of a server 100. FIG. 2 illustrates an example of a hardware configuration of a server 100. FIG. 10 is a diagram showing an example of a screen output by an output unit 230. FIG. 5 is a diagram showing an example of a first screen 500 visually showing loss factors. FIG. 6 is a diagram showing an example of a second screen 600 visually showing loss factors. FIG. 7 is a diagram showing an example of a third screen 700 visually showing loss factors. FIG. 8 is a diagram showing an example of a heat map screen 800. An example of a screen 900 showing the time progression of each index is shown. FIG. 10 is a diagram showing an example of a screen 1000 for a history of remote advice. FIG. 11 is a diagram showing an example of a screen 1100 on which a comment has been inserted. FIG. 2 is a diagram showing an example of an internal processing procedure of the system 10.

Hereinafter, embodiments of the technical concepts of the present disclosure will be described with reference to the drawings. In the following description, identical components are designated by the same reference numerals. Their names and functions are also the same. Therefore, detailed descriptions thereof will not be repeated.

<A. Application example>
1 is a diagram showing an example of the configuration of a system 10 according to the present embodiment. With reference to FIG. 1, application examples of the technology disclosed herein, problems that may arise in factories and the like, and terms used in this specification will be described.

(a. System configuration to which the technology of the present disclosure can be applied)
A system 10 according to this embodiment includes one or more sensor devices 110 and a server 100. The system 10 may communicate with user terminals 120, 130, and 140. According to an embodiment, the system 10 may include some or all of the terminals 120, 130, and 140.

The sensor device 110 has a sensor function and a communication function with the server 100. According to one embodiment, the sensor device 110 may be configured to be connectable to one or more sensors. According to another embodiment, the sensor device 110 may incorporate one or more sensors. Hereinafter, unless otherwise specified, a sensor refers to a sensor built into the sensor device 110 or a sensor connected to the sensor device 110.

According to one embodiment, the sensors include optical sensors, including temperature sensors, humidity sensors, cameras, and vibration sensors. Furthermore, the sensors include any sensor, such as an acceleration sensor, a gyro sensor, a pressure sensor, a gas sensor, a current sensor, a voltage sensor, and a switch.

The sensor device 110 transmits a signal (sensor data) to the server 100 via wireless or wired communication. According to one embodiment, the sensor device 110 may transmit an analog signal to the server 100. According to another embodiment, the sensor device 110 may transmit a digital signal to the server 100.

The server 100 stores signals acquired from the sensor devices 110 in storage 303 (see Figure 3). The server 100 also analyzes the signals acquired from the sensor devices 110. The server 100 also provides a mechanism for encouraging users to improve the operation of the production equipment based on the results of the signal analysis. According to one embodiment, the server 100 may be implemented as one or more devices, or as a virtual machine, container, or the like in a cloud environment. More specifically, the server 100 presents information regarding the production efficiency of the production equipment to a first user. The first user may be a consultant or the like who proposes operational improvements to the production equipment to end users. The server 100 acquires, from the first user, improvement information for the production equipment based on the information regarding the production efficiency of the production equipment. The server 100 presents improvement information for the production equipment based on the information regarding the production efficiency of the production equipment to a second user. The second user may be a company that owns the production equipment or an employee of that company. In this way, the server 100 is not simply a function for detecting abnormalities in the production equipment, but also has a series of functions for encouraging the second user to improve the operation of the production equipment. Hereinafter, unless otherwise specified, "first user" refers to a consultant who supports improvements to the productivity of production equipment. Furthermore, "second user" refers to the company that owns the production equipment or an employee of that company. Furthermore, second users include managers and supervisors of manufacturing companies (companies that own production equipment). "User" includes first users and second users. In this specification, "improvement" includes all improvements related to production operations, such as production planning, personnel allocation, and equipment replacement.

Terminal 120 is a terminal owned by the second user. Terminal 120 accepts input of reports and the like related to production equipment. As an example, the reports may include any information related to production management, such as the total number of processed products produced and the number of defective products. Terminal 120 transmits the reports to server 100. Server 100 may receive reports from one or more terminals 120.

The server 100 stores the reports acquired from the terminal 120 in the storage 303 along with the signals acquired from the sensor device 110. The server 100 may also provide the analysis results of both the signals and the reports to the first and second users.

The terminal 130 is a terminal (device) owned by the first user. The terminal 130 receives information related to the production efficiency of the production equipment from the server 100. The terminal 130 displays the information related to the production efficiency of the production equipment on a display. The first user refers to the information related to the production efficiency of the production equipment and considers improvement plans for the production equipment. The first user inputs improvement plans for the operation of the production equipment into the terminal 130. The terminal 130 transmits the input improvement plans for the operation of the production equipment to the server 100. The server 100 may be configured to be able to communicate with one or more terminals 130.

The terminal 140 is a terminal (device) owned by the second user. The terminal 140 receives improvement proposals for the operation of the production equipment from the server 100. The terminal 140 displays the improvement proposals for the operation of the production equipment on a display. The second user refers to the improvement proposals for the operation of the production equipment. In this way, the second user can improve the business flow and/or the configuration of the production equipment based on advice from the first user. The server 100 may be configured to be able to communicate with one or more terminals 140.

According to one embodiment, terminal 120 and terminal 140 may be the same terminal. According to another embodiment, terminals 120, 130, and 140 may have an application installed that communicates with server 100. According to yet another embodiment, server 100 may provide various functions to terminals 120, 130, and 140 as web applications. In this case, terminals 120, 130, and 140 may exchange data with server 100 via a browser.

(b. Problems that may arise during the operation of production facilities and solutions)
Next, we will explain issues that may arise in production facilities to which IoT technology is applied. As mentioned above, IoT technology has been used in recent years to inspect production facilities for abnormalities. However, small and medium-sized businesses that have no knowledge of DX technology or automation technology may not be able to fully utilize IoT technology. More specifically, small and medium-sized businesses may not be able to fully analyze information obtained by IoT technology and provide feedback on the results of this analysis to the operation of production facilities. This problem arises from the fact that IoT technology is used to detect abnormalities in production facilities, but is not widely used to improve business processes.

Therefore, the system 10 according to this embodiment provides users with a function for improving workflows using information obtained through IoT technology. More specifically, the system 10 acquires signals from sensor devices 110 installed in the production equipment and user input (documents) using the acquisition unit 210 (see Figure 2). The system 10 analyzes the signals, or the signals and document input, using the analysis unit 220 (see Figure 2) to obtain information related to the production efficiency of the production equipment. The system 10 outputs information related to the production equipment using the output unit 230 (see Figure 2). The output unit 230 outputs information related to the production efficiency of the production equipment to the first user's terminal 130. In practice, the output unit 230 transmits screen information to the terminal 130. This allows the first user (consultant) to identify problems with the production equipment or workflows and explore improvement proposals. The acquisition unit 210 acquires production equipment improvement information based on information related to the production efficiency of the production equipment from the first user (consultant). The output unit 230 outputs production equipment improvement information to the second user's device. In practice, the output unit 230 sends screen information to the terminal 140. This allows the second user (the company that owns the production equipment or an employee of that company) to view advice from the first user (the consultant).

As described above, system 10 generates information related to the production efficiency of production equipment based on information acquired from sensor device 110. Alternatively, system 10 generates information related to the production efficiency of production equipment based on information acquired from sensor device 110 and terminal 120. Unlike simple anomaly detection information provided by conventional IoT technology, information related to the production efficiency of production equipment can be used to improve the operation of the production equipment. Furthermore, system 10 provides a series of mechanisms that enable a first user to identify problems in the operation of production equipment and provide improvement proposals to a second user. This allows the first user to efficiently provide consulting services for improving the operation of production equipment. Furthermore, the second user can efficiently improve their own operations.

(c. Terms used herein)
Next, definitions of terms used in this specification will be explained. In this specification, the term "system" encompasses a configuration consisting of one or more devices, such as a server. The term "system" also encompasses a virtual machine or container built in a cloud environment, or a configuration consisting of at least a part of these. According to one embodiment, the system may be connected to input/output devices such as a display and a keyboard and used by a user. According to another embodiment, the system may provide various functions to a user as a service or web application via a network. In this case, the user may use the system's functions via a browser or client software installed on their own terminal.

In this specification, "server" also includes a configuration consisting of one or more devices, a virtual machine or container built in a cloud environment, or a configuration consisting of at least a part of these.

In this specification, the term "terminal" includes any information processing device, such as a personal computer, workstation, server, tablet, or smartphone. A terminal may also be a combination of these.

In this specification, the term "sensor device" includes an integrated sensor element and information processing device, as well as an information processing device configured to be connectable to a sensor element. Sensor devices also have communication capabilities via wireless and/or wired communication. Sensor devices also have the ability to transmit analog or digital signals acquired from the sensor element to external devices.

In this specification, "production equipment" includes any equipment installed in a factory or the like. Production equipment is sometimes simply referred to as equipment. As an example, production equipment includes equipment that processes any product, equipment that packages any product, and equipment that inspects any product. Products include any product, such as machine parts, resin parts, food, and pharmaceuticals. Production equipment also includes one or more devices. For example, suppose a production line for a certain processed product is a combination of 10 devices. In this case, each individual device is production equipment. Furthermore, the 10 devices (the production line itself) are also production equipment. Hereinafter, for the sake of distinction, a single device included in a production line may be referred to as "production equipment, equipment, or equipment." The entire production line may also be referred to as "entire production equipment."

In this specification, "processed products" refers to products that have been manufactured, processed, packaged, or inspected by production equipment. For example, products that have been directly processed by production equipment are processed products. Products that have only been inspected by production equipment are also processed products. Products that have been packaged by production equipment are also processed products. Processing by production equipment includes any process, such as attaching a label to a product.

In this specification, a "defective product" is a processed product (product) that has a defect in the manufacturing process. For example, a processed product that has been deformed or missing a portion when processed by production equipment is a defective product. A processed product that fails to pass inspection by production equipment is a defective product. Conversely, a "good product" is a processed product that has been manufactured, processed, or packaged properly in the manufacturing process. Good products also include those that pass inspection.

As used herein, a "document" refers to data containing any information related to production equipment or processed products. For example, a document may include the quantity of processed products, the quantity of defective products, the number of processed product orders, the number of processed product shipments, etc.

In this specification, "information related to the production efficiency of production equipment" refers to data obtained by analyzing data from sensor devices 110 and/or terminals 120. As an example, information related to the production efficiency of production equipment includes the time availability rate, performance rate, non-defective product rate, loss factors, and overall equipment efficiency.

In this specification, "load time" refers to the time when all production equipment is operating, or the entire time when processed products are being produced. For example, suppose a company uses all of its production equipment to produce processed products from 10:00 to 18:00. In this case, the load time is 8 (18 - 10) hours. Load time also includes the time when some production equipment (devices) is stopped.

In this specification, "operating time" refers to the time that an individual piece of production equipment (device) is in operation. For example, suppose a certain production facility is equipped with Device 1, Device 2, and Device 3. The load time is eight hours, and during that time, only Device 1 is stopped for two hours due to a problem. In this case, the operating time of Device 1 is six hours.

In this specification, "availability" refers to the percentage of operating time during load time for each production facility (device). The availability is calculated using the formula "availability = (load time - downtime) / load time." The availability will be explained later with reference to Figure 4.

In this specification, "performance rate" refers to the production volume per operating hour. Performance rate is calculated using the formula "performance rate = (reference cycle time x production volume) / operating hour." Performance rate will be explained later with reference to Figure 4.

In this specification, "quality rate" refers to the percentage of quality products among the processed products manufactured per unit time. The quality rate is calculated using the formula "quality rate = (processed quantity - defective quantity) / processed quantity." The number of processed products and the number of defective products here refer to the number of processed products and the number of defective products per unit time. The quality rate will be explained later with reference to Figure 4.

In this specification, "overall equipment efficiency" is an index that indicates the overall efficiency of production equipment. Overall equipment efficiency may include an index that indicates the overall efficiency of all production equipment on a production line. Overall equipment efficiency may also include an index that indicates the overall efficiency of individual production equipment (devices). Overall equipment efficiency is calculated using the formula "availability rate x performance rate x non-defective product rate." Overall equipment efficiency will be explained later with reference to Figure 4.

In this specification, a "loss factor" refers to a factor that leads to a loss of production time (a factor that reduces the time utilization rate). For example, a loss factor can be calculated from input changes of each sensor device 110, signals from a change point input device, etc. According to one embodiment, each sensor device 110 may detect the movement of personnel on the production line, whether personnel are waiting, whether a specific process has been completed, whether a processed product has passed through a specific location, etc. Loss factors will be explained later with reference to Figures 5 to 7.

<B. Device configuration>
Fig. 2 is a diagram showing an example of the functional configuration of server 100. According to one embodiment, the various functions shown in Fig. 2 may be realized as programs. In this case, control unit 301 (see Fig. 3) of server 100 may load a program for realizing the various functions shown in Fig. 2 from storage 303 (see Fig. 3) to memory 302 (see Fig. 3) and execute the program. According to another embodiment, some or all of the various functions shown in Fig. 2 may be realized as hardware.

The server 100 comprises an acquisition unit 210, an analysis unit 220, and an output unit 230. The acquisition unit 210 comprises a data acquisition unit 211 and an input unit 212. The analysis unit 220 comprises a data storage unit 221, an overall efficiency calculation unit 222, an availability calculation unit 223, a performance rate calculation unit 224, a quality rate calculation unit 225, and a loss factor analysis unit 226. The output unit 230 comprises an overall equipment efficiency display unit 231, an availability display unit 232, a performance rate display unit 233, a quality rate display unit 234, and a loss factor display unit 235. The output unit 230 further comprises a heat map display unit 236, a performance trend display unit 237, a remote advice performance display unit 238, a comment display unit 239, and a data output unit 240.

The acquisition unit 210 acquires various signals from the sensor device 110 and various data from the terminal 120. The acquisition unit 210 outputs the acquired information (signals and data) to the analysis unit 220 or the output unit 230.

The data acquisition unit 211 acquires forms, sensor data (signals), and input from a change point input device. The data acquisition unit 211 stores the acquired various information in the data storage unit 221. The input unit 212 accepts user input. The user input may include forms, input from a first user, input from a second user, etc. The data acquisition unit 211 stores a portion of the acquired information in the data storage unit 221. The data acquisition unit 211 outputs a portion of the acquired information to the output unit 230. According to one embodiment, the data acquisition unit 211 and the input unit 212 may be realized as a single function.

The analysis unit 220 analyzes the acquired data. The analysis unit 220 performs calculations related to the operational efficiency of the production equipment.

The data storage unit 221 stores various information acquired from the data acquisition unit 211 and the input unit 212. According to one embodiment, the data storage unit 221 may be represented as a relational database table, or in any other data format such as JSON (JavaScript (registered trademark) Object Notation).

The overall efficiency calculation unit 222 references the data stored in the data storage unit 221 to calculate the overall equipment efficiency. The overall equipment efficiency is an index that shows the overall efficiency of each piece of production equipment (device). The overall equipment efficiency is calculated using the formula "availability rate x performance rate x non-defective product rate."

The availability calculation unit 223 calculates the availability by referencing the data stored in the data storage unit 221. The availability is the ratio of operating time to load time for each production facility (device). The availability is calculated using the formula "availability = (load time - downtime) / load time".

The performance utilization rate calculation unit 224 calculates the performance utilization rate by referencing the data stored in the data storage unit 221. The performance utilization rate indicates the production volume per operating hour. The performance utilization rate is calculated using the formula "performance utilization rate = (reference cycle time × production volume) / operating hour".

The yield rate calculation unit 225 calculates the yield rate by referencing the data stored in the data storage unit 221. The yield rate indicates the proportion of good products among the processed products manufactured per unit time. The yield rate is calculated using the formula "Grade rate = (processed quantity - defective product quantity) / processed quantity." The number of processed products and the number of defective products here refer to the number of processed products and the number of defective products per unit time.

The loss factor analysis unit 226 calculates loss factors by referencing the data stored in the data storage unit 221. The loss factors are obtained by analyzing signals output by various sensors.

The output unit 230 visualizes the various information obtained from the analysis unit 220 and presents it to the user. According to one embodiment, the output unit 230 displays the various information on a UI (User Interface) provided by the server 100. The UI provided by the server 100 is, for example, a web application screen. According to another embodiment, the output unit 230 transmits display data to an application installed on the user's terminal. In this case, the application installed on the user's terminal generates a display screen based on the display data.

The overall equipment efficiency display unit 231 visualizes the overall equipment efficiency and presents it to the user. The availability rate display unit 232 visualizes the availability rate and presents it to the user. The performance rate display unit 233 visualizes the performance rate and presents it to the user. The quality rate display unit 234 visualizes the quality rate and presents it to the user. The loss factor display unit 235 visualizes the loss factors and presents it to the user.

The heat map display unit 236 presents a heat map to the user. The heat map visualizes, for example, the operating rate of each individual piece of production equipment (device). By referring to the heat map, the user can estimate which device or which process is causing a bottleneck.

The performance trend display unit 237 presents the user with the trends in production performance by the production equipment. The remote advice performance display unit 238 presents the user with the history of advice provided by the first user (consultant). The second user (the company that owns the production equipment or an employee of that company) can check past improvement efforts and their results by referring to the trends in production performance and the history of advice.

The comment display unit 239 overlays advice from the first user (consultant) on various displays. The first user can add their own comments (improvement suggestions, etc.) to the overall equipment effectiveness screen, the time availability screen, the performance availability screen, and the non-defective product rate screen via the comment display unit 239. The first user can also add their own comments (improvement suggestions, etc.) to the loss cause screen, heat map screen, etc. via the comment display unit 239.

The data output unit 240 outputs various types of information as files, etc. The data output unit 240 can output files, reports, etc. that include various graphs, etc. The various graphs include, for example, graph and numerical information that the output unit 230 can output to a UI.

Figure 3 shows an example of the hardware configuration of server 100. Server 100 includes a control unit 301, memory 302, storage 303, an external device IF (Interface) 304, an input IF 305, an output IF 306, and a communication IF 307.

The control unit 301 may execute programs to realize various functions of the server 100. The control unit 301 may be configured, for example, with at least one integrated circuit. According to one embodiment, the server 100 may include, for example, at least one CPU (Central Processing Unit), at least one GPU (Graphics Processing Unit), at least one FPGA (Field Programmable Gate Array), at least one ASIC (Application Specific Integrated Circuit), or a combination thereof.

Memory 302 stores programs executed by control unit 301 and data referenced by control unit 301. In some aspects, memory 302 can be realized by DRAM (Dynamic Random Access Memory), SRAM (Static Random Access Memory), or the like.

Storage 303 is a non-volatile memory that stores programs executed by control unit 301 and data referenced by control unit 301. In this case, control unit 301 executes programs read from storage 303 to memory 302 and references data read from storage 303 to memory 302. In some aspects, storage 303 can be realized by a hard disk drive (HDD), a solid state drive (SSD), an erasable programmable read-only memory (EPROM), an electrically erasable programmable read-only memory (EEPROM), flash memory, or the like.

The external device IF 304 can be connected to any external device, such as a printer, scanner, or external HDD. In one aspect, the external device IF 304 can be implemented by a USB (Universal Serial Bus) terminal or the like.

The input IF 305 can be connected to any input device, such as a keyboard, mouse, touchpad, or gamepad. In some aspects, the input IF 305 can be realized by a USB terminal, a PS/2 terminal, a Bluetooth (registered trademark) module, or the like.

The output IF 306 can be connected to any output device, such as a cathode ray tube display, a liquid crystal display, or an organic electroluminescence (EL) display. In some aspects, the output IF 306 can be implemented by a USB terminal, a D-sub terminal, a DVI (Digital Visual Interface) terminal, an HDMI (registered trademark) (High-Definition Multimedia Interface) terminal, a DisplayPort terminal, etc.

The communication IF 307 is connected to other devices via a wired or wireless network. In one aspect, the communication IF 307 can be realized by a wired LAN (Local Area Network) port, a Wi-Fi (registered trademark) (Wireless Fidelity) module, or the like. In another aspect, the communication IF 307 can send and receive data using communication protocols such as TCP/IP (Transmission Control Protocol/Internet Protocol) and UDP (User Datagram Protocol).

<C. Screen configuration>
Next, with reference to FIGS. 4 to 11 , the screens presented to the user by the system 10 will be described. Each screen presented to the user by the system 10 includes at least a portion of information related to the production efficiency of the production equipment. Each screen includes information on the availability rate, performance rate, quality rate, loss factors, and/or overall equipment efficiency as part of the information related to the production efficiency of the production equipment. The system 10 also provides an input screen for production equipment improvement information, a history screen, and a screen showing the temporal trends of each indicator (such as overall equipment efficiency). The production equipment improvement information includes remote advice input by a first user to the system 10. The production equipment improvement information also includes countermeasures input by a second user to the system 10. For example, the countermeasures are countermeasures considered based on the remote advice input by the first user to the system 10.

Figure 4 is a diagram showing an example of a screen output by the output unit 230. According to one embodiment, the output unit 230 may display each of the screens shown in Figure 4 on a display connected to the server 100. According to another embodiment, the output unit 230 may transmit each of the screens shown in Figure 4 or information for displaying each of the screens to a user's terminal (terminal 130, 140, etc.). In this case, the user's terminal displays the screen on the display based on the received information. Note that the information on each of the screens 401 to 404 can be displayed in any format other than a pie chart, such as a bar graph.

Screen 401 visually displays the overall equipment effectiveness. As mentioned above, the overall equipment effectiveness is an index that shows the overall efficiency of the entire 1,000-volume facility or each piece of production equipment (device). The overall equipment effectiveness is calculated using the formula "availability rate x performance rate x non-defective product rate."

As mentioned above, information about the production efficiency of production equipment includes information about the overall equipment efficiency of the production equipment. For example, the analysis unit 220 calculates the overall equipment efficiency based on the availability rate, performance rate, and quality rate. The output unit 230 outputs the overall equipment efficiency screen 401 based on the calculation results of the analysis unit 220.

Increasing the efficiency of production operations is essential for the growth of the manufacturing industry. Therefore, system 10 presents users with screen 401, which visually displays overall equipment effectiveness as an indicator of production operation efficiency. For example, a second user (e.g., a manager or supervisor of a manufacturing company) can understand the current capabilities of their company's production operations by referring to screen 401. Furthermore, by referring to screens 401, 900, 1000, etc., the second user can recognize the effects of past improvement activities and determine whether the improvements are functioning properly. Furthermore, a first user (consultant) can provide appropriate advice to the second user by referring to screen 401.

According to one embodiment, system 10 may be capable of visually displaying the overall efficiency of the entire production facility. According to another embodiment, system 10 may be capable of visually displaying the overall efficiency of individual pieces of production equipment (machines).

Screen 402 visually shows the availability rate of production equipment. As mentioned above, the availability rate is the percentage of operating time during load time for each piece of production equipment (device). Operating time is the load time minus the downtime. The availability rate is calculated using the formula "availability rate = (load time - downtime) / load time".

As mentioned above, information related to the production efficiency of the production equipment includes information related to the time availability rate of the production equipment. For example, the system 10 acquires first information indicating whether the production equipment is operating from the sensor device 110. The analysis unit 220 calculates the operating time of the production equipment based on the first information. The analysis unit 220 may also calculate the load time of the production equipment based on the first information. Alternatively, the load time may be input into the system 10 in advance. The analysis unit 220 calculates the time availability rate based on the load time and operating time of the production equipment. The output unit 230 outputs the time availability rate screen 402 based on the calculation results of the analysis unit 220.

When it comes to improving the efficiency of production operations, the utilization rate of each production facility (device) is one of the most important management items. A decrease in the utilization rate of each production facility (device) directly leads to a decrease in production volume. Therefore, system 10 presents the user with screen 402, which visually shows the equipment's utilization rate as an indicator of production operation efficiency. For example, a second user (e.g., a manager or supervisor of a manufacturing company) can understand the current capabilities of their company's production operations by referring to screen 402. Furthermore, by referring to screens 402, 900, 1000, etc., the second user can recognize the effects of past improvement activities and determine whether the improvements are functioning properly. Furthermore, a first user (consultant) can provide appropriate advice to the second user by referring to screen 402.

According to one embodiment, system 10 may have the ability to visually display the availability of the entire production facility. According to another embodiment, system 10 may have the ability to visually display the availability of individual pieces of production facility (device).

Screen 403 visually displays the performance rate of the production equipment. As mentioned above, the performance rate indicates the production volume per operating hour. The performance rate is calculated using the formula "performance rate = (reference cycle time x production volume) / operating hour."

As mentioned above, information related to the production efficiency of the production equipment includes information about the performance utilization rate of the production equipment. For example, the system 10 acquires second information indicating the completion of production of processed products from the sensor device 110. The analysis unit 220 can calculate the production volume of processed products for each standard cycle time based on the second information. The analysis unit 220 calculates the performance utilization rate based on the production volume and operating time for each standard cycle time. The output unit 230 outputs the performance utilization rate screen 403 based on the calculation results of the analysis unit 220.

When it comes to improving the efficiency of production operations, the difference between the planned production volume (performance) per unit time and the actual production volume is one of the most important management items. A decline in the performance utilization rate of each production facility (device) directly leads to a decrease in production volume. Therefore, system 10 presents the user with screen 403, which visually displays the equipment performance utilization rate as an indicator of production operation efficiency. For example, a second user (e.g., a manager or supervisor of a manufacturing company) can understand the current capabilities of their company's production operations (production volume per unit time) by referring to screen 403. Furthermore, by referring to screens 403, 900, 1000, etc., the second user can recognize the effects of past improvement activities and determine whether the improvements are functioning properly. Furthermore, a first user (consultant) can provide appropriate advice to the second user by referring to screen 403.

According to one embodiment, system 10 may have the ability to visually display the performance rate of the entire production facility. According to another embodiment, system 10 may have the ability to visually display the performance rate of individual production facilities (devices).

Screen 404 visually displays the yield rate. As mentioned above, the yield rate indicates the proportion of good products among the processed products produced per unit time. The yield rate is calculated using the formula "Grade rate = (Processed quantity - Defective quantity) / Processed quantity."

As mentioned above, information about the production efficiency of the production equipment includes information about the yield rate of the production equipment. For example, the signal from the sensor device 110 or the report from the terminal 120 includes third information about processed products and/or defective products. The system 10 acquires this third information. The analysis unit 220 can calculate the number of processed products and the number of defective products based on the third information. The analysis unit 220 calculates the yield rate based on the number of processed products and the number of defective products. The output unit 230 outputs the yield rate screen 404 based on the calculation results of the analysis unit 220.

In improving the efficiency of production operations, the yield rate per unit time is one of the most important management items. A decline in the operating rate of each production facility (device) not only leads to a decrease in production volume, but also to a decline in the quality of the entire processed product. Therefore, system 10 presents the user with screen 404, which visually shows the yield rate of processed products manufactured by the production facility as an indicator of the efficiency of production operations. For example, a second user (e.g., a manager or supervisor of a manufacturing company) can understand the current capabilities of their company's production operations (yield rate per unit time) by referring to screen 404. Furthermore, by referring to screens 404, 900, 1000, etc., the second user can recognize the effects of past improvement activities and determine whether the improvements are functioning properly. Furthermore, a first user (consultant) can provide appropriate advice to the second user by referring to screen 404.

According to one embodiment, system 10 may have a function to visually display the yield rate of the entire production facility. The yield rate of the entire production facility is the yield rate throughout the entire production process. According to another embodiment, system 10 may have a function to visually display the yield rate of individual production facilities (devices). The yield rate of individual production facilities (devices) is the yield rate in each process.

Figure 5 is a diagram showing an example of a first screen 500 visually indicating loss factors. Figure 6 is a diagram showing an example of a second screen 600 visually indicating loss factors. Figure 7 is a diagram showing an example of a third screen 700 visually indicating loss factors. According to one embodiment, the system 10 may display the first screen 500, the second screen 600, and the third screen 700 on a display connected to the server 100. According to another embodiment, the system 10 may transmit the first screen 500, the second screen 600, the third screen 700, or information for displaying these screens to the user's terminal 130, 140.

As mentioned above, loss factors are factors that lead to lost production time (factors that reduce the time utilization rate). For example, loss factors can be determined from input changes of each sensor device 110, signals from the change point input device, etc. That is, the analysis unit 220 can determine loss factors based on signals from the sensor devices 110. For example, a second user (e.g., a manager or supervisor of a manufacturing company) can determine the priority of tasks for improving production operations by referring to the visualized loss factors. In the example of Figures 5 to 7, a large loss (equipment stoppage) occurred in the "Start Preparation" process. In this case, the second user can understand that improvement of the "Start Preparation" process is essential. Furthermore, the first user (consultant) can provide appropriate advice to the second user by referring to the first screen 500, second screen 600, and third screen 700. In this way, the first and second users can effectively utilize limited resources and efficiently improve production operations by referring to the first screen 500, second screen 600, and third screen 700.

Figure 8 shows an example of a heat map screen 800. A heat map visualizes the operating rate of each device in each process. By referring to the heat map screen 800, the first and second users can identify bottlenecks on the production line. This allows the first and second users to get an overview of the entire manufacturing process and determine which device is causing the bottleneck. Furthermore, the second user (e.g., the manager or supervisor of a manufacturing company) can prioritize improvements to bottleneck devices.

Figure 9 shows an example of a screen 900 showing the temporal progression of each index. The screen 900 showing the temporal progression of each index is generated and output by the performance progression display unit 237. The screen 900 showing the temporal progression of each index visualizes the temporal progression of the overall equipment effectiveness and its decomposed indices, such as availability rate, performance rate, and non-defective rate. By referring to the screen 900, the first and second users can understand changes in the operating status of each device. This allows the first and second users to narrow down the issues and causes of problems on the production line and take effective measures to improve production operations. Furthermore, the first and second users can understand the effects of past business reforms by referring to the screen 900 and the screen 1000 (see Figure 10) described below.

Figure 10 is a diagram showing an example of a remote advice history screen 1000. As described above, the system 10 has a function that allows a first user (consultant) to send remote advice to a second user (a company that owns production equipment or an employee of that company). Each time remote advice is received, the system 10 stores the history of that remote advice in storage 303. Then, in response to a user request, the system 10 outputs the remote advice history screen 1000. The screen 1000 can be viewed by both the first user and the second user. In other words, the system 10 can display on the screen 1000 the history of past improvement information entered by the first user as improvement information for the production equipment.

According to one embodiment, system 10 also records measures actually taken by the second user based on the advice of the first user, and related information. System 10 provides a UI that allows the first user to record measures in association with the remote advice. System 10 associates the information obtained via the UI with the remote advice of the second user and stores it in storage 303. By referring to screen 900 and screen 1000, described below, the first and second users can understand the effects of past business reforms. Furthermore, by keeping a record of improvement work (measures to improve productivity) carried out in the past, the second user can accumulate know-how for improving production work. Furthermore, the second user can review advice received from the first user in the past.

Figure 11 is a diagram showing an example of a screen 1100 with a comment inserted. The system 10 has a function for adding comments to various analysis screens (e.g., screens 401 to 900) output by the output unit 230. Users can add comments to various analysis screens via a UI provided by the system 10. For example, a first user can use this function to leave a comment as advice on various analysis screens. The system 10 transmits the screen on which the second user has written the comment to the second user's terminal 130. That is, the screen on which the second user has written the comment is transmitted to the first user's terminal 130 as part of the second user's remote advice. The second user refers to the comments about peculiarities in the actual analysis data. In this way, the first user can clearly present bottlenecks in production operations and countermeasures to address them to the second user. That is, the system 10 can display, on screen 1100, the first user's additional advice on information regarding the production efficiency of the production equipment as improvement information for the production equipment.

The system 10 provides the first user's terminal 130 with a UI for writing remote advice. The UI may have a function for accepting text advice and a function for adding comments to various analysis screens. Information written by the first user in the UI for remote advice is sent to the server 100. The server 100 stores the received remote advice in storage 303. The server 100 also transmits the remote advice to the second user's terminal 140. The remote advice provided to the second user's terminal 140 may include some or all of the various analysis screens with text, audio, video, and comments inserted.

As described with reference to Figures 4 to 11, the first user and the second user can work together to improve production operations by using the functions provided by system 10. Furthermore, the second user can accumulate know-how for improving production operations by referring to the history of remote advice, etc. The first user is a consultant, and the second user is a company that owns production equipment or an employee of that company. An example of a consulting procedure using system 10 is shown below.

First, the first user checks the overall equipment effectiveness, availability rate, performance rate, non-defective product rate, loss factors, etc. presented by the system 10. This allows the first user to identify items that are contributing to inefficiencies on the production line. The first user can also check how the numerical values of each item change over time.

Secondly, by referring to the heat map screen 800, the first user can confirm which equipment is causing a bottleneck in each process. The first user can understand the causes of loss in the bottleneck equipment and derive improvement plans to maximize productivity.

Third, the first user may periodically provide remote advice to the second user by referring to various screens provided by system 10. According to one embodiment, the remote advice may be exchanged via text via system 10. According to another embodiment, the remote advice may be provided using a web conferencing system. The first and second users can easily hold discussions during the web conference by sharing the screen provided by system 10. While sharing the screen provided by system 10, the first user may ask the second user about the direct cause of a bottleneck in a process. Furthermore, the first user may present specific improvement proposals to the second user based on the results of the interview.

Fourth, the first user records specific improvement proposals agreed upon with the customer (second user), for example, on the remote advice history screen 1000. This allows past advice to be stored as knowledge in the system 10.

Fifth, the second user clarifies the numerical targets, responsibilities, and deadlines by checking the remote advice history screen 1000, and works to improve the business. The second user registers the improvement work (measures) that has actually been carried out or is planned to be carried out in the system 10. According to one embodiment, the screen 1000 may be configured to allow the improvement work (measures) to be written in. In this case, the second user can write a record of the measure related to a certain row of remote advice on the screen 1000.

Sixth, the first user can continuously check changes in the numerical targets for improving production operations by referring to the various screens provided by system 10, and provide further advice as necessary. The second user can continuously grasp the numerical values for production operations by referring to the various screens provided by system 10, and can confirm the effects of operational improvements.

By repeating steps 1 through 6 above, the first user can support the second user in fostering a culture of business improvement and growing production operations.

D. Flowchart
12 is a diagram showing an example of an internal processing procedure of system 10. According to an embodiment, control unit 301 may load a program for performing the processing of FIG. 12 from storage 303 into memory 302 and execute the program. In another aspect, part or all of the processing may be realized as a combination of circuit elements configured to perform the processing.

In step S1210, the system 10 acquires data from the sensor device 110 and/or the terminal 120. The system 10 stores the acquired various data in the data storage unit 221.

In step S1220, the system 10 analyzes the acquired data. This analysis includes analysis of availability, performance, non-defective product rate, loss factors, and overall equipment effectiveness.

In step S1230, the system 10 generates a screen for the first user and displays the screen. For example, the system 10 generates screens such as those shown in Figures 4 to 11. According to one embodiment, the system 10 transmits the screen for the first user to the first user's terminal 130. Alternatively, the system 10 transmits data for generating the screen for the first user to the first user's terminal 130.

In step S1240, system 10 accepts input from the first user. The input may be advice regarding improvements to production operations. As an example, the input may be text, audio, or a comment added to an analysis screen such as screen 1100.

In step S1250, the system 10 generates a screen for the second user and displays the screen. For example, the system 10 generates screens such as those shown in FIGS. 10 and 12. The system 10 may also provide the second user with screens such as those shown in FIGS. 4 to 9. According to one embodiment, the system 10 transmits the screen for the second user to the second user's terminal 140. Alternatively, the system 10 transmits data for generating the screen for the second user to the second user's terminal 140.

In step S1260, the system 10 outputs data. The system 10 may output any information, such as various analysis screens, advice, countermeasure records, and reports, as files.

As described above, system 10 according to this embodiment generates information related to the production efficiency of production equipment based on information acquired from sensor device 110. Alternatively, system 10 generates information related to the production efficiency of production equipment based on information acquired from sensor device 110 and terminal 120. Unlike simple anomaly detection information provided by conventional IoT technology, information related to the production efficiency of production equipment can be used to improve the operation of the production equipment. Furthermore, system 10 provides a series of mechanisms that enable a first user to identify problems in the operation of production equipment and provide improvement proposals to a second user. This allows the first user to efficiently provide consulting services for improving the operation of production equipment. Furthermore, the second user can efficiently improve their own operations.

The embodiments disclosed herein should be considered illustrative in all respects and not restrictive. The scope of the present disclosure is indicated by the claims, not by the above description, and is intended to include all modifications within the meaning and scope of the claims. Furthermore, the disclosures described in the embodiments and each modification are intended to be implemented, to the extent possible, either alone or in combination.

10 System, 100 Server, 110 Sensor device, 120, 130, 140 Terminal, 210 Acquisition unit, 211 Data acquisition unit, 212 Input unit, 220 Analysis unit, 221 Data storage unit, 222 Overall efficiency calculation unit, 223 Time availability calculation unit, 224 Performance availability calculation unit, 225 Good product rate calculation unit, 226 Loss factor analysis unit, 230 Output unit, 231 Overall equipment efficiency display unit, 232 Time availability display unit, 233 Performance availability display unit, 234 Good product rate display unit, 235 Loss factor display unit, 236 Heat map display unit, 237 Performance trend display unit, 238 Remote advice performance display unit, 239 Comment display unit, 240 Data output unit, 301 Control unit, 302 Memory, 303 Storage, 304 External device IF, 305 Input IF, 306 Output IF, 307 Communication IF, 401, 402, 403, 404, 800, 900, 1000, 1100 Screen, 500 First screen, 600 Second screen, 700 Third screen.

Claims (12)

an acquisition unit that acquires signals from sensor devices installed in the production equipment and user input;
an analysis unit that analyzes the signal or the signal and the input of the form to obtain information regarding the production efficiency of the production equipment;
a display unit for displaying information related to the production equipment;
the information regarding the production efficiency of the production equipment includes information visually indicating a relationship between loss factors of the production equipment and downtime of the production equipment;
the display unit outputs information regarding the production efficiency of the production equipment to a device of a first user;
the acquisition unit acquires, from the first user, improvement information for the production equipment based on information on the production efficiency of the production equipment;
The display unit outputs improvement information about the production equipment to a device of a second user. The production facility includes a plurality of facilities,
The system according to claim 1 , wherein the analysis unit is configured to generate information visually indicating a relationship between loss factors of the production equipment corresponding to each of the plurality of pieces of equipment and downtime of the production equipment. 3. The system according to claim 2, wherein the analysis unit is configured to generate information visually showing a relationship between loss factors of the production equipment corresponding to each of the plurality of pieces of equipment on a daily basis and downtime of the production equipment. the first user is a consultant who supports improvement of productivity of the production facility,
The system according to any one of claims 1 to 3 , wherein the second user is an employee of a company that owns the production facility. the information about the production efficiency of the production equipment includes information about the time availability rate of the production equipment;
the signal includes first information indicating whether the production facility is operating;
The analysis unit
Calculating an operating time of the production equipment based on the first information;
The system according to claim 1 , wherein the availability rate is calculated based on the load time and the operating time of the production equipment. the information about the production efficiency of the production facility includes information about the capacity utilization rate of the production facility;
the signal includes second information indicating completion of production of the workpiece;
The analysis unit
calculating a production amount of the processed product per reference cycle time based on the second information;
The system according to claim 5 , wherein the performance rate is calculated based on the production volume for each reference cycle time and the operating time. The information about the production efficiency of the production equipment includes information about the non-defective product rate,
the signal or report includes third information regarding the processed product and/or the defective product;
The analysis unit
Calculating the number of processed products and the number of defective products based on the third information;
The system according to claim 6 , wherein the non-defective product rate is calculated based on the number of processed products and the number of defective products. the information about the production efficiency of the production facility includes an overall equipment efficiency of the production facility;
The system according to claim 7 , wherein the analysis unit calculates the overall equipment effectiveness based on the availability rate, the performance rate, and the non-defective product rate. 4. The system according to claim 1, wherein the improvement information of the production equipment includes history information of past improvement information input by the first user. 4. The system according to claim 1 , wherein the improvement information for the production facility includes additional information of advice by the first user added to information on the production efficiency of the production facility. acquiring signals from sensor devices installed in the production equipment and inputs from a user;
and a step of analyzing the signal or the signal and the input of the form to obtain information relating to the production efficiency of the production equipment, the information relating to the production efficiency of the production equipment including information visually showing the relationship between loss factors of the production equipment and downtime of the production equipment;
displaying information about the production efficiency of the production facility on a device of a first user;
acquiring, from the first user, improvement information for the production equipment based on information on the production efficiency of the production equipment;
and outputting the improvement information of the production facility to a device of a second user. acquiring signals from sensor devices installed in the production equipment and inputs from a user;
and analyzing the signal or the signal and the input of the form to obtain information relating to the production efficiency of the production equipment, the information relating to the production efficiency of the production equipment including information visually showing the relationship between loss factors of the production equipment and downtime of the production equipment;
displaying information about the production efficiency of the production facility on a device of a first user;
acquiring, from the first user, improvement information for the production equipment based on information on the production efficiency of the production equipment;
and outputting the improvement information of the production equipment to a device of a second user.