Development of an Alternative Production Plan Automatic Execution System to Realize Continuous Production in case of Equipment Failure

Abstract

This research aims to develop a system which detects equipment failure even in the absence of a worker and resumes production within minutes. The proposed system generates alternative production process plans in advance according to the failure mode. When the failure is detected in the production, the selection method provides the emergency stop, the evacuation operation, and the alternative plan selection based on the facility data. As a result of the verification of this system, continued production was realized with 54% of the production capacity, whereas 0% of the production capacity when the system is not used. The proposal system made it possible to resume production by executing an alternative in 13.9 seconds from equipment failure.