Field Operator Support System

Outline of the support system

There has been increased social demand for the prevention of industrial accidents a due to frequent occurrence in recent years. As a means of dealing with the human factors of such accidents, which account for 75% of the causes, TOYO has developed the Field Operator support systemb(FOSS) jointly with the Research Institute of Human Engineering for Quality Life. This was a three-year project consigned by METI. The system supports the field workers engaged in operations, maintenance and inspection at large-scale factories and plants, such as refineries and petrochemical plants, enabling them to engaged in their tasks in a highly efficient and reliable manner.

Explosion Proof Devices

Support devices for field work

Compact, light-weight and explosion-proof support devices for field work (wearable camera) has been developed jointly with IDEC Corporation. The camera can take movie at worksites while the operator is wearing it, enabling themovie and voice recordings to be distributed.

Explosion proof	：	EciblllBT3
Battery	：	Ni-MH battery(operation time: Two hours or more)
Weight	：	Body 620g Camera 150g
Camera	：	CMOS 310,000 dot
Movie	：	QVGA, 15～20fps,MPEG4
Wireless type	：	IEEE802. 11b(SD Card)
Storage	：	1GB(SD Card)

Wireless LAN and Storage

System development

System for managing field work

This system monitors the work situation at the worksites using images and voice recordings through the central control room. The system uses explosion-proof equipment at the worksites, thereby enabling information to be shared in real-time with the worksites.

Database of　field work

Data representing the work situation, consisting of images photographed while expert and unskilled workers conducted field work, may be accumulated in databases, and the data may be used for conducting various types of analysis.

System outline diagram

Ergonomic analysis technology

Based on the data obtained by the support equipment, the behavior of workers when engaged in field work is analyzed utilizing the technologies of the National Institute of Advanced Industrial Science and Technology. Time-series data including movements, shift in directions of gaze and suchlike, is analyzed to the kinds of action or operation. And the statistic analysis of these data is used to identify differences in the work behavior of expert and unskilled workers, and to automatically identify the circumstances where work that differed from the conventional practice arose. These findings would help in the identification of know-how possessed by experienced workers.

Advantages

Real-time sharing

Using a wireless LAN, the situation at the worksites may be confirmed in real-time at the central instrument room, making it possible to issue instructions on the work and operations. This practice enables the following:

The prevention of similar measuring gauges, valves and suchlike from being operated erroneously
Instructions on operating procedures, know-how and linked operations
Immediate understanding of abnormal situations at the worksites, thereby facilitating decision-making
Monitoring the safety of workers

Share information between site and central control room

Technical skill transfer

Images are recorded using a wireless LAN or placed in storage making it possible to conduct data analysis to extract the operations and know-how of expert workers. This process helps is passing on the operational procedures and skill of expert workers to younger employees and to improve the work environment. The extracted images can be compiled into collections of images representing know-how and multi-media manuals, thereby providing effective training manuals that are most suitable for the worksite.

Standardization of the work procedures
Education/training (operation manuals, model operations by expert workers)

Transfer the knowledge of experienced worker

Improvement by work procedure analysis

Analyses of the work procedures based on images that have been recorded and stored help improve the work procedures at the sites and facilities. The images also serve as evidence for determining whether there was any error in the operating procedures or whether a specific process has actually been performed.

Field Operator Support System