JP2001251095A - Manufacture control system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacture control system wherein production stop due to arrangement for supplying a surface-mounting component is suppressed to minimum, in a surface-mounting process in which the surface-mounting component is mounted on a printed wiring board (Pt plate) for soldering in many-kind/ small-quantity production system. SOLUTION: A fixed set component deciding means is provided wherein a production plan corresponding component list is generated from a CAD information for Pt plate, a production plan for it, and a component information for components to be use, and a fixed set component is decided based on a production plan corresponding board average and a line operation condition. A fixed set component distributing means is provided wherein a fixed set component among the production plan corresponding component list is sequentially set, initially to a mounter capable of collective set and then to a plurality of mounters after no mounter capable of collective set is available, so that the total mounting time with the mounter is averaged.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manufacturing management system, and more particularly to a method for supplying surface mounted components in a surface mounting process of mounting and soldering surface mounted components on a printed wiring board under a small-lot production system. The present invention relates to a production management system capable of minimizing production stoppage due to setup change.

2. Description of the Related Art In the manufacturing process of electronic equipment such as communication equipment and information processing equipment, SOP (Small Outline Package) or QFP in which chip parts such as resistors and capacitors, digital integrated circuits and analog integrated circuits are packaged.
(Quad Flat Package) and other surface mount components (usually "SM
D ". This is "Surface Mount Device"
Is an abbreviation that takes the initials of ) Is mounted on a printed circuit board and soldered.

[0003] Therefore, rationalization and efficiency of the surface mounting process are the most important issues for rationalization and efficiency improvement of the manufacturing process of electronic devices such as communication devices and information processing devices.

[0004] Here, the surface mounting process usually includes a surface mounting process of the printed wiring board, that is, solder paste printing, mounting of surface mounted components and soldering by reflow soldering, and a back surface of the printed wiring board. Mounting process,
That is, applying an adhesive for fixing the surface-mounted component, mounting the surface-mounted component on the adhesive, temporarily fixing the surface-mounted component by curing the adhesive, and attaching the leaded component to the hole on the printed wiring board. There are lead insertion and soldering by flow soldering.

[0005] Of these, lead insertion and flow soldering of components with leads are outside the scope of the present invention.

Accordingly, solder paste printing on the surface of a printed wiring board, mounting of surface mount components, and reflow soldering.
Soldering by soldering, applying adhesive for fixing surface mounted components on the back side of the printed wiring board, mounting surface mounted components on the adhesive, temporarily fixing and mounting the surface mounted components by curing the adhesive・ Soldering by soldering and the work associated therewith are objects of rationalization and efficiency improvement according to the present invention.

[0007] When mass-producing a specific kind of limited type, it is only necessary to continuously supply fixed parts. Therefore, a dedicated manufacturing apparatus, all of which are optimized for the specific kind, is introduced. Is the best solution for rationalization and efficiency.

However, if there are many types of products to be manufactured and the number of products per type is small, that is, in the case of small-lot production of many types, it is not possible to put in a dedicated manufacturing apparatus, and it is not possible to combine general-purpose manufacturing apparatuses. Therefore, a production line in which parts supplied by products are changed is inevitable.

[0009] Therefore, in a production line in which various kinds of products are produced in small quantities, the efficiency of the work of changing the parts supplied by the product affects the efficiency of the manufacturing process.

A surface mounting line is generally a chip mounting machine dedicated to chip components, and a general-purpose mounting machine capable of mounting chip components and package components having multiple terminals with fine pitches (in the sense that components of different forms can be mounted). It is also called “deformed component mounting machine” or “deformed mounting machine.”).

[0011] Then, in a typical product of various kinds of small-volume production, it is necessary to mount about 40 types of surface mount components per type of printed wiring unit on a parts feeder attached to the mounting machine, and set them on the mounting machine. . Attach one type of surface mount component to the part feeder attached to the mounting machine and set it on the mounting machine. (I have used it several times without explanation of its meaning, but this is called "setup change" or "setup".) .) Takes about 2 minutes / type of part. Therefore, it takes 40 minutes to change the setup of 40 types of surface mount components by two workers.

Further, the problem is that even if the number of manufactured printed wiring units of the same type is large or
This means that a setup time of 0 minutes is required. In other words, in the case of a printed wiring unit with a small number of manufactures, the time required for the setup change of the surface mounted component may be longer than the time required for mounting the surface mounted component on the printed wiring unit.

Therefore, even in the case of a printed wiring unit whose number of production is small, it is possible to construct a production management system capable of minimizing the time required for the changeover of the surface mount components and increasing the efficiency of the production line of various kinds and small quantities. I have been waiting.

[0014]

2. Description of the Related Art Heretofore, the following measures have been devised in order to minimize the production stoppage time due to setup change.

The first one is to automate the setting of the parts feeder to the parts feeder set table.

[0016] This is to automate the setting of the parts feeder to the parts feeder set table by introducing the parts feeder automatic warehouse and the parts feeder mounting robot, and to automatically replace the parts feeder set table. According to this, the parts that will be required next during the manufacture of the printed wiring board unit will be automatically replaced at the end of production by preparing the parts feeder set table, so the line will be stopped The time can be reduced to about 2 minutes.

The greatest advantage is that the effect of labor saving is great, but there is a problem that the manufacturing system is expensive and can be applied only to a special mounting machine. In addition, for the same component, there are two types: a component reel being surface-mounted and a component reel being set up outside.
There is also a problem that one reel is required.

The second is a method in which component parts and feeders of a plurality of surface mount printed wiring board units are collectively prepared, and one part and feeder is replaced at the end of the production of the previous product. About 20 minutes.

An advantage is that the total mounting time is lengthened by combining a product with a large number of products and a product with a small number of products, and during that time the components are ready to be prepared. On the other hand, there is a problem that two reels, a component reel during surface mounting and a component reel during external setup, are required.

The third method is a system in which parts feeders prepared in the external setup are exchanged for each part feeder set table.

In this method, a surface mount component is set on a separately placed parts feeder set table, and the parts feeder is replaced collectively for each set table. The internal setup time is about 10 minutes.

An advantage is that complete external setup is possible, but there is a problem that it can only be applied to a specific mounting machine that can replace parts feeder set tables all at once. There is also a problem that two reels, a component reel in the middle and a component reel in the outer setup, are required.

In addition, when the number of parts manufactured is very small, parts cannot be replaced in the external setup in time, and the park feeder
Production stoppage due to setup change due to set / table exchange cannot be ignored.

What has been devised is a method in which surface mount components are fixedly set on a parts feeder set table.

In this method, frequently used surface mount components are fixedly set on a parts feeder set table, and other components are collectively set on a parts feeder set table with a plurality of printed wiring board units. The external setup time is (the number of types of surface mount components requiring setup change other than the surface mount components to be fixedly set) × 2 minutes ÷ (the number of workers).

An advantage is that the replacement of the surface-mounted components is limited to the surface-mounted components excluding the surface-mounted components to be fixedly set, so that the number of set types of the surface-mounted components is reduced and the component preparation time is minimized. Therefore, even in the case of lot production, we try to make preparations for parts in time.
By combining the method of setting the feeders in groups and the method of collectively replacing the parts feeder set table, the setup change time can be further reduced.

Another advantage is that only one reel of the same part is required.

[0028]

However, the system in which the surface mount components are fixedly set on the parts feeder set table has the following disadvantages.

The first drawback is that, in order to achieve a fixed set of parts feeders on a mounting machine to the extent that the effect of shortening the production stoppage time by minimizing the setup change time is increased, the number of mounting machines must be reduced. The point is that it is necessary to increase it from about three times to about five times.

A second drawback is that the optimal number of types of fixedly mounted surface mount components cannot be determined objectively or logically.

A third disadvantage is that it is difficult to balance the mounting time among a plurality of mounting machines because the parts are set fixedly.

In view of the above problems, the present invention minimizes production stoppage due to changeover of surface mount components in a surface mounting process of mounting and soldering surface mount components on a printed wiring board under a variety of small production systems. It is an object of the present invention to provide a manufacturing management system that can be made into a computer.

[0033]

For the first disadvantage, the frequency of use of surface mount components applied to products to be manufactured in the future is calculated with reference to a manufacturing plan, and the most effective surface mount components are calculated. Means to determine the parts to be fixedly set.

By the above means, the most effective surface mount component is selected and determined as a component to be fixedly set.
The component preparation work can be shortened without significantly increasing the number of mounted machines.

As for the second disadvantage, there is a means for converting the component information and the mounting machine information into a database and determining the number of types and the set positions of the fixed set components in accordance with the ratio of the fixed set components to the setup components.

According to the above-mentioned means, the number of types and the set positions of the fixed set components can be determined in accordance with the ratio between the fixed set components and the setup components. Therefore, the optimal number of the surface mount components to be fixedly set is objectively determined. Can be determined.

As a third disadvantage, there is a means for arranging the surface mounting components to be fixedly set in such a manner that the mounting time is balanced among a plurality of mounting machines.

According to the above-mentioned means, it becomes possible to arrange the surface mounting components to be fixedly set in a plurality of mounting machines with the mounting time being balanced.

Furthermore, in accordance with the distribution of the number of manufactured products, parts are distributed to the mounting machine by giving priority to a specific printed wiring board, or all parts used in a certain production plan are frequently used. A means to select whether to sort in order, a means to assign frequently appearing parts to multiple mounting machines redundantly, and a means to select so that the mounting time of the mounting machine to mount the parts is balanced, and to mount the setup parts to the product By adopting a means for dynamically setting according to the completion information or the manufacturing schedule, it is possible to realize a manufacturing management system capable of minimizing the production stoppage due to the change of the surface mount component supply setup.

[0040]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the technology of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a functional block diagram of the first embodiment of the present invention.

In FIG. 1, reference numeral 1 denotes a central processing unit (abbreviated as “CPU” in the figure, which is an abbreviation of “Central Proccesser Unit”) for controlling the entire manufacturing management system. Reference numeral 2 denotes fixed set component determining means for rationally determining fixed set components. Reference numeral 3 denotes fixed set component distribution means for rationally distributing the components determined as fixed set components by the fixed set component determining means 2 to the mounting machine. Reference numeral 4 denotes a part other than the fixed set parts, that is, a set-up part set position determining means for rationally determining the set position of the set-up parts on the mounting machine. Numerical control data creation means for deciding whether or not to implement (in the figure, abbreviated as “NC data creation means”. “NC” means “Numeri
cal Control (numerical control). ) And 6 are surface mounting line control means for controlling a line for mounting the surface mounting components on the printed wiring unit.

7 is a loader for supplying a printed wiring unit to a line, 8 is a solder printing machine for printing a solder paste on the sequentially supplied printed wiring units, and 9 is a solder printing machine.
An adhesive applicator for applying an adhesive to the printed wiring unit is a component mounting machine for mounting a surface mount component on a solder paste or an adhesive, and 13 is a reflow machine.
A rear row furnace for soldering the surface mount components to the printed wiring unit by soldering, and a surface mount line is configured by the reflow furnace 13 after the loader 7.

Numeral 14 denotes design information by a computer (abbreviated as "CAD information" in the figure. "CAD" is an abbreviation of "Computer Aided Design". 15 is a production plan at a predetermined time, 16 is a setup component selection table which is information of setup components, and 17 is information of the entire surface mount component (this is referred to as “component information”). ), 18 is information of the component mounting machines 10 to 12 (this is referred to as “mounting machine information”), and 19 is a line operating condition (this is referred to as “line operating condition”). .), 2
0 is set position information of all the surface mount components to be set on the mounting machine (this is referred to as a “component set list”).

Then, the fixed set part determining means 2
AD information 14, production plan 15, setup part selection table 16,
Component information 17, mounting machine information 18, and line operating conditions 19
Is used to determine fixed set parts.

The fixed set component distribution means 3 and the setup component set position determination means 4 use the component information 17 and the placement machine information 18 to determine the distribution of fixed set components and the set position of the setup component, and Create a separate parts set list.

Further, the numerical control data creating means 5 has a CAD
Numerical control data is created using the information 14, the production plan 15, the set-up part selection table 16, the part information 17, and the part set position information determined by the fixed set part allocating means 3 and the set-up part set position determining means 4.

Finally, the surface mounting line control means 6 controls the surface mounting line using the numerical control data.

In FIG. 1, a solid solid line represents a bus, a thin solid arrow represents an information flow, and a thick solid line represents a manufacturing flow.

In the first embodiment of the present invention, first, the optimum set number of fixed set components and the fixed set components themselves are determined by the fixed set component determination means, and then the fixed set components are allocated by the fixed set component distribution means. The parts are distributed to the mounting machines, and subsequently, the set-up parts setting position determining means allocates the prepared parts to the mounting machines and determines the set positions. After that, the numerical control data and the part set list are created by the numerical control data creating means, and finally the production is started.

Hereinafter, the description will proceed focusing on the fixed set component determining means 2, the fixed set component allocating means 3, and the setup component set position determining means, which are features of the present invention, including the numerical control data creating means and the manufacturing process. go.

FIG. 2 shows the fixed set part determining means 2 of FIG.
In the flowchart for determining the fixed set part, the information necessary for determining the fixed set part is also shown.

Here, solid thick arrows indicate the flow of processing, and thin solid arrows indicate the flow of information.

FIG. 3 shows an example of CAD information, FIG. 4 shows an example of component information, FIG. 5 shows an example of mounting machine information, and FIG. 6 shows a surface mounting line corresponding to the mounting machine information of FIG. FIG. 7 is an example of a set-up component selection table, FIG. 8 is an example of a production plan, and FIG. 9 is an example of a line operating condition, which is used as a reference when explaining the flowchart of FIG. It is illustrated.

Hereinafter, the procedure for determining the fixed set components will be described in detail along the reference numerals in FIG. 2. Before entering a specific description, CAD information, component information, mounting machine information, arrangement of component mounting machines, setup An example of a parts selection table, a production plan, and line operating conditions will be outlined.

First, CAD information is organized for each product drawing number. Of which, item numbers are assigned corresponding to part numbers,
2 which is the reference of the component mounting position on the printed wiring unit
Two fiducial marks also appear as parts and appear first. Then, a component symbol representing a component name for each item number, an X coordinate and a Y coordinate of a mounting position, and an angle indicating a mounting direction (“θ” in the figure)
It is labeled. ), The drawing number of the component, the number 1 or 2 representing the surface of the printed wiring unit on which the component is mounted (indicated as “mounting surface” in the figure), and the block number.

Next, the part information includes a part shape code for each part drawing number, a packing style indicating what kind of container the part is supplied in, a part type indicating the shape and package of the part, and a normal air state for the part. A humidity rank indicating a permissible limit time that can be left inside, a cartridge type, (omitted halfway), a mounting time, and a setup time are described.

Next, the mounting machine information indicates the number of channels on which reels can be set for each component setting section (abbreviated as "set section" in the figure) of the mounting machine forming the surface mounting line. Is abbreviated as “CH.” This is called “CHANNEL
"Is an abbreviation using the first two letters. In the following, "CH" is also indicated in the figure. ) And the number of channels in which trays can be set. In this case, it is assumed that each mounting machine has two component setting units.

FIG. 6 shows the arrangement of component mounting machines on the surface mounting line corresponding to the mounting machine information.

Next, the setup part selection table indicates the attributes of the parts whose setup is to be changed. Components having any of the attributes shown here are determined as setup components.

Next, the production plan includes a production number, a production number, and a production number for each drawing number (product drawing number) of a printed wiring unit as a product.
The scheduled date for supplying parts to the manufacturing site (scheduled release date) and the scheduled completion date of the product are described.

Finally, the line operation conditions include the number of products to be grouped (the number of grouped products), the number of setup workers,
It describes an unbalance rate in component mounting, a method of allocating components to a plurality of component mounting machines by giving priority to a board or averaging a board, and a work mode such as two shifts.

Now, the processing of the fixed set part determining means will be described in detail.

S1. Create a list of parts used for production planning.

The first process consists of the production plan shown in FIG.
From the AD information, all parts used when manufacturing a product in a production plan within a predetermined period are listed up, and the number of appearances and the number of use are calculated.

Next, the attribute information of the component described in the component information of FIG. 4, that is, the component shape code, the packing style, the number of occupied channels, the component type, and the humidity, using the component drawing number of the listed component as a key. Add rank, cartridge type and lead pitch.

Next, the listed parts are sorted in the following order.

(1) Since the parts having the part attributes described in the setup part selection table of FIG. 7 cannot be fixedly set, they are moved to the end of the listed parts.

(2) Parts other than the above parts are sorted in descending order of appearance frequency.

As a result of the above sorting, first, components other than the set-up components are arranged in the order of appearance frequency, and thereafter, the set-up components are arranged.

Next, the following calculation is performed to fill in the columns of the used parts list corresponding to the production plan.

(3) Calculate the ratio of the number of appearances of each part to the number of appearances of the entire part (appearance ratio:%), and further calculate the accumulation of the ratio of the number of appearances from the top (cumulative appearance ratio:%). I do.

(4) The usage ratio (%) and the cumulative usage ratio (%) are calculated for the number of parts used.

(5) Calculate the cumulative number of the occupied channels (accumulated channel number) for each component in order from the top.

(6) For each component, the mounting time is calculated by (number of used components) × (mounting time of a single component in the component information).

(7) For each component, the setup time is calculated by (the number of appearances) × (the setup time in the component information).

By the above-described processing, as shown in FIG. 10, the columns of the used parts list corresponding to the production plan are filled except for the mounting machine number and the part set position (in the figure, simply referred to as “set position”). . However, in FIG. 10, detailed descriptions of the component shape, packing style, component type, humidity rank, parts feeder, lead pitch, mounting time and setup time are omitted.

S2. The cumulative appearance ratio and the cumulative usage ratio with respect to the number of component types (equal to the item number) in the list of used components corresponding to the production plan in FIG. 10 are read, and a graph of the number of fixed component types and their occupancy is created.

This corresponds to item numbers 100, 200, 3 in FIG.
The cumulative appearance ratio and the cumulative use ratio at 00,..., 1000 may be read and graphed.

For example, if the number of types of fixed parts is 400, the cumulative appearance ratio is 73 from the list of used parts corresponding to the production plan.
% And the cumulative usage ratio is 85%.

S3. The number of parts, the number of parts, the number of occupied channels, the number of products,
Find the mounting time and setup time.

This can be obtained by combining the production plan shown in FIG. 8 and the CAD information for each product drawing number shown in FIG.

Steps S1 to S3 are the preparation processing for determining the fixed parts and optimizing the arrangement of the set-up parts.

S4. A combination of the number of channels of the fixed set component and the number of setup components is made in units of the mounting machine number and the number of component sets / channels in correspondence with the mounting machine information of FIG.

In this case, the reel information is obtained from the mounting machine information shown in FIG.
Since the maximum number of channels is 800, the number of setup component channels is 0 when the number of fixed set component channels is 800, and the number of setup component channels is 800 when the number of fixed set component channels is 0. This is described in the first and second rows of the fixed set component / setup component distribution table.

S5. The number of fixed set component channels and the number of setup component channels are divided by the average number of occupied channels for each production plan in FIG. 11, and each channel number is converted into the number of component types.

In this case, the average number of occupied channels per board in each production plan in FIG. 11 is 1.5 channels / part. The result of the division is described in the third and fourth rows of the fixed set component / setup component distribution table.

S6. The occupancy rate for the total number of component types in the case of the number of fixed set component types in the third row of the fixed set component / setup component distribution table is determined from the cumulative appearance ratio in graph 1.

For example, when the number of fixed set component types is 400 in the third row of the fixed set component / setup component distribution table, the fixed set component occupancy is 73%. The fixed set component occupancy thus obtained is described in the fifth row of the fixed set component / setup component distribution table.

Further, (the number of parts used on the average of the boards by the production plan in FIG. 11) × (1− (the occupation ratio with respect to the whole parts)) is (the number of parts to be set up) / (product).

For example, when the fixed set component occupancy is 73%, 400 × (1−0.73) = 10.8 is the number of setup component types / product. The values thus determined are described in the sixth row of the fixed set component / setup component distribution table.

S7. By dividing the number of parts that can be set up and set up in the fourth row of the fixed set parts / setup parts distribution table by the value of the sixth row of the fixed set parts / setup parts distribution table, how many parts can be simultaneously placed in the setup part set section The number of products that can be set in a group that indicates whether they can be set is determined.

For example, if the number of fixed set component channels is 70
In the case of 0, the number of settable parts is 66.7 and the number of settable parts / product is 9.6, so the number of group settable products is 7.0. The value thus determined is described in the seventh row of the fixed set component / setup component distribution table.

S8. The continuous operation time of the group / set board is obtained as follows.

That is, (average mounting time / number of mounted machines) ×
It is calculated by (loading machine unbalance rate) x (average number of products manufactured) x (number of products that can be set in a group). For example, when the number of fixed set component channels is 700, the average mounting time is 3.05 minutes, the number of mounted machines is 4, the unbalance rate of mounted machines is double, the average number of manufactured is 6.7, and group setting is possible. Since the number of products is 7.0, the continuous operation time of the group / set board is 1.2 hours. The value thus determined is described in the eighth row of the fixed set component / setup component distribution table.

S9. Similarly, the setup time is calculated by the following.

In other words, it is calculated by (fixed set parts / set-up part distribution table, the number of kinds of parts that can be set-up in the fourth row) × (average setup time) / number of workers. For example, when the number of fixed set component channels is 700, the number of parts that can be set up and set is 66.7, and the average setup time is 2 minutes. Therefore, when the number of workers is two, the setup time is 1.1 hours. The value thus determined is described in the ninth row of the fixed set component / setup component distribution table.

As described above, the fixed set component / setup component distribution table is completed through steps S4 to S9. Then, the number of channels of the fixed set component and the number of channels of the setup component are determined by the following check routine.

S10. Select the place where the difference between continuous operation time and setup time is the largest.

In this case, the number of fixed set component channels is 7
At 00, the continuous operation time is 1.2 hours and the setup time is 1.1 hours, and the difference is maximum.

By the way, the number of group / set figure numbers is required to be 5 or more from the average of the boards by production plan in FIG. 11, and when the number of fixed set component channels is 700, any product in the production plan is manufactured. It needs to be possible.

Therefore, it is determined whether the above solution satisfies the above two conditions.

S11. It is determined whether the number of boards that can be set in a group is 5 or more.

S12. If the number of boards that can be set in a group is less than 5 in step S11 (No), the number of set-up component setting locations is increased by one, and the verification in step S11 is performed again.

S13. In step S11, if the number of boards that can be set in the group is 5 or more (Yes), it is determined whether or not the setup components of any boards can be set.

If the number of set-up parts and the number of channels are insufficient to set all the set-up parts on any of the printed wiring boards (No), the set-up part set location is increased by one in step S12. , The verification in steps S11 and S13 is performed again.

In step S13, if any of the setup parts of the printed wiring board can be set (Ye
In s), the fixed set component is determined, and the process ends.

In this case, since the number of products that can be set in a group is 7, the process can proceed from step S11 to step S13. Then, if it is determined in step S13 that the set-up parts of all the boards can be set in the set-up part setting units at 100 locations, the process ends.

Next, based on the processing result by the fixed set component determining means, the fixed set components are distributed to the mounting machines on which the fixed set components are set, and the setting positions are determined.

FIG. 13 is a flowchart of the fixed component distribution means. Hereinafter, the processing of the fixed component distribution unit will be described along the reference numerals in FIG.

S21. After setting the mounting time of each mounting machine to 0, the mounting time of the entire setup component is calculated first.

As described above, the number of channels of the fixed set parts is determined to be 700 by the fixed set part determining means. In the list of used parts corresponding to the production plan in FIG. It is. Therefore, in the list of used parts corresponding to the production plan in FIG. 10, if the sum of the mounting times is obtained for the parts having the accumulated channel number of 700 or more, the mounting time of the setup parts is obtained.

S22. This is added to the mounting time of the setup component mounting machine.

The initial value of the mounting time of the setup component mounting machine is 0.
, So the mounting time is now set on the setup component mounting machine. Specifically, as described above, the number of channels of the set-up parts is 100, and the production stoppage due to the setup change is unlikely to occur when the mounting machine located behind in the line is used as the mounter for the set-up parts. No. No. 4 is set to the setup part, and the part setting part is No. 4. 8 is assumed.

S23. The first part in the list of used parts corresponding to the production plan in FIG. 10 is selected.

S24. It is determined whether or not there is a mounted machine having a vacant channel for setting the selected component.

In this case, the loading machine No. No. 4 part setting section No. 4 No. 8 is a set part of the set-up parts, so that the determination target is the mounting machine No. 8. No. 1 to No. Three
And installed machine No. No. 4 part setting section No. 4 7

S25. If it is determined in step S24 that there is a mounting machine on which the selected component can be set (Yes), the mounting machine with the shortest total mounting time is selected from the above mounting machines.

In this case, since the first part of the fixed set part has been selected, the mounting machine No. 1 to N
o. The channel of No. 3 is empty, and the mounting time is 0. Therefore, the loading machine No. No. 1 to No. 3 can be assigned to the first part in the list of used parts corresponding to the production plan in FIG.

S26. The mounting time and the number of occupied channels are added to the mounting machine on which the component is set.

S27. In the column of mounting machine number in the list of used parts corresponding to the production plan in FIG. 10, the number of the mounting machine for which the part is to be set is written.

S29. The next part in the list of used parts corresponding to the production plan shown in FIG. 10 is selected, and the process jumps to step S24. Steps S24 to S29 are repeated until there is no more mounting machine on which the selected part can be set.

At first, the sorting is performed mainly on the mounting machine on which the set-up parts are not set.
After the steps S29 to S29 are repeated, the mounting machine No. for setting up the set-up parts. No. 4 part setting section No. 4 7, the fixed set parts are also sorted.

S30. If it is determined in step S24 that the selected component cannot be set on any of the mounting machines (No), it means that all the components to be set on each mounting machine are complete. Put these parts in the front and rear two sets,
Sort the parts so that they have the same number of parts and determine the set position.

S31. In the column of the mounting machine number in the list of used parts corresponding to the production plan in FIG. 10, the number of the set position at which the part is set is entered.

S32. Then, a component set table of the fixed components is created for each mounting machine, and the process is terminated.

With this, the mounting machine on which the fixed set component is set and the setting position are determined. The mounting machine number and the set position number are common to the printed wiring unit of the product.

Next, a list of parts to be used for each product is created for each printed wiring unit of the product, and a mounting machine on which set-up parts are set and a setting position are determined.

First, a list of used components for each board is created in the order of production from CAD information and component information of boards in the production plan.

The format of the used parts list for each board is as shown in FIG. 14. First, the part drawing number and the number of parts used for the printed wiring unit of a specific product drawing number are copied from the CAD information. The component attributes from the component information to the setup time are copied from the component information using the number as a key, and finally, the mounting machine number and the set position number related to the fixed set component determined by the fixed set component distribution means are copied.

In this state, the mounting machine number and the set position number relating to the setup parts are blank. Therefore,
The mounting machine number and the setting position number are determined for the blank parts in the columns of the mounting machine number and the setting position number.

In the above example, the number of channels allocated to the setup components is 100, and No. 4 part setting section No. 4 Since it is known that the setting should be made to 8, in this case, only the setting position needs to be determined.

However, in general, there may be a plurality of mounting machines on which set-up parts are set. In this case, the necessary channels are allocated as the mounting machines for the setup parts in order from the mounting machine behind the production line. Then, which set-up parts are to be assigned to which mounter can be determined by the same procedure as the fixed set part assigning means, so that the set-up part number and the set-up number for the set-up parts can be determined.

By adding the mounting machine number and the set position number for setting the set-up parts determined in this way to the table of FIG. 14, the list of used parts by board for the printed wiring unit of a specific figure number is completed. In the following, similarly, the mounting machine number and the set position number of the setup parts are determined for the printed wiring board units in the next production order in the production plan (in the above example, since the mounting machine number is fixed, the set position number is determined. You only need to decide on the number.)

At this time, for the same parts as those used in the printed wiring unit for which the mounting machine number and the set position number of the set-up parts have been previously determined, the same mounting machine number and the set position number are determined. Avoid redundant component sets and reduce the number of component sets.

In this way, if the placement machine and the setting position of the setup component are determined until all the component setting sections of the placement machine for setting the setup component are filled, the component setting section of the placement machine for setting the setup component is completed. It is possible to determine the machine number and set position number of the set-up parts for the group of printed wiring units before they are all filled (this is the group of printed wiring units that can be produced in one setup).

In the above description, the procedure for determining the set position of the set-up parts for only the printed wiring units included in the production plan has been described. It is also possible to determine the part setting position.

The set list of the set-up parts is completed in addition to the set list of the fixed set parts completed by the processing of the fixed set part allocating means, so that the set list of all the parts is completed. You.

Since the set list of the fixed set parts is determined according to the production plan, the set list of the fixed set parts is not changed during the production plan period, but the set list of the setup parts is not changed. Is changed each time all of the printed wiring units produced and supplied in response to one setup are completed, and the production is continued in combination with a single fixed set component set list.

Up to this point, the technique of determining the fixed set component type and distributing the fixed set component and the setup component, which are the features of the present invention, have been described.

For a while, the procedure of the determination of the fixed set component type, the distribution of the fixed set components and the setup components, the creation of numerical control data, and the production procedure will be described.

First, the procedure for creating the numerical control data is as follows.

First, the mounting surface is divided for each part drawing number in the CAD information (the mounting information is already divided in the CAD information of FIG. 3).

The mounting machine number and the set position number of the fixed set parts and the set-up parts determined by the fixed set part allocating means and the set-up part allocating means are copied to the information by using the part drawing number as a key.

Next, the CAD information is divided for each mounting machine number. That is, the CAD information is divided by adding the mounting machine number after the product drawing number and the version number of the CAD information in FIG. 3, and the component information of the component information is added to convert the CAD information into numerical control data for each mounting machine. . The conversion technique is widely applied to CAD information and CAM information (where “CAM” is “Computer Aided Ma
Abbreviation for "nufacturing," meaning production under computer control. ), The detailed description is omitted.

Finally, numerical control data is created for the solder printing machine and the adhesive coating machine by the usual technique, and the numerical control data for the entire production line is completed.

Now that all the information for starting production has been prepared, production is performed in the following procedure.

First, fixed set parts are set in each mounting machine according to the fixed set part set list.

Next, the set-up parts are collected according to the set-up part set list of the first product group, set on a collective exchange trolley (parts feeder set table) and set on the mounting machine.

Next, the printed wiring board to be produced is put in a rack, and put into a loader which is the leading equipment of the surface mounting line.

Each equipment reads the ID given to the printed wiring board while the printed wiring board flows through the line, automatically changes the width of the conveyor, changes the numerical control data, and prints the solder paste. , Fixed set parts mounting, setup parts mounting, reflow soldering.

Next, the substrates forming the same group are successively put into the loader, and the manufacture of the same group of substrates is continued.

On the other hand, at the same time when the production of the first printed wiring board unit is started, the collection of the next set-up parts is started according to the set-up part set list of the next group created in advance.

Then, when the components of the last printed wiring unit of the first product group have been mounted, the collective exchange cart is replaced and set on the mounting machine. This starts production of the next product group.

Thereafter, the production of a plurality of product groups is performed by repeating the above.

As described in detail above, according to the present invention,
Decision of fixed set parts, distribution of fixed set parts to loading machines and distribution of setup parts to loading machines can be performed rationally, minimizing the disadvantage of stopping production due to setup waiting. it can.

[0157] The description of the first embodiment of the present invention is completed above, and then, the description of the second embodiment of the present invention is started.

Although the form of the functional block diagram of the second embodiment of the present invention is the same as that of FIG. 1, the processing of the fixed set component allocating means is different, so only the fixed set component allocating means will be described.

In the preparatory process, first, products having the same product drawing number having different production numbers and scheduled release dates in a production plan are added together and the number of products is added, and the products are sorted in descending order of the number of products.

Then, for each manufacturing drawing number, using the CAD information and the component information, a list of used components for each board surface is created in the same manner as described above. Calculate the total loading time. Fig. 1
FIG. 9 is an example of a list of parts used according to board surface according to the second embodiment of the present invention shown in FIG.

According to the above calculation results, the order of the components on the list of used components by board surface is sorted in the order of the total mounting time.

On the other hand, in the list of used parts corresponding to the production plan in FIG. 10, for the parts whose cumulative number of channels is 700 or more, the number of channels of the fixed set parts is 70 as described above.
0, so the mounted machine number is No. 4 is assumed.

Then, the fixed set components are distributed to the mounting machine in the following procedure.

FIG. 16 is a flow chart of the fixed set component allocating means according to the second embodiment of the present invention. Hereinafter, description will be made along the reference numerals in FIG.

S41. Select the list of parts used by board surface with the largest number of products.

S42. Select the first component in the selected component list for each board surface.

S43. It is determined whether or not the mounting machine number of the selected component is blank.

When the mounted machine number is not blank (No)
In step S4, the machine number has already been determined.
Jump to 8. It should be noted that the first is a blank.

S44. If the mounting machine number is blank in step S43 (Yes), it is determined whether there is a mounting machine on which the component can be set.

If there is no mounting machine on which the part can be set (No), the process jumps to step S50. At first, it can be set naturally.

S45. In step S24, if there is a mounting machine on which the component can be set (Yes), a mounting machine with the shortest total mounting time is selected among the mounting machines on which the fixed set component is mounted, and S46. Add the installation time and the number of channels to the mounted machine.

S47. Write the mounting machine number in the list of used parts corresponding to the production plan and the list of used parts by board surface.

S48. It is determined whether or not the component distributed to the mounting machine is the last component in the list of used components by board surface.

If it is determined that the part is the last part (Ye
In s), the process jumps to step S52.

S49. If it is determined in step S48 that the component is not the last component (No), the process proceeds to step S41.
Then, the next part in the list of used parts for each board surface selected in is selected, and the process jumps to step S43.

S50. If it is determined in step S44 that there is no mounting machine on which the selected component can be set (No), it means that all the components to be set on each mounting machine are complete. These parts are allocated to the two front and rear set parts so that the number of parts is the same, and the set position is determined.

S51. The set position number is written in the production plan-compatible part list and the board-part-specific part list, and the flow advances to step S54.

Step S4 until the final part is obtained.
Steps 3 to S49 are repeated.

S52. If it is determined in step S48 that the board is the last board (Yes), it is determined whether the board on which the fixed set components have been distributed is the last board.

When it is determined that the base is the last base (Ye
In s), the process jumps to step S50.

S53. If it is determined in step S52 that the board is not the last board (No), the production number is selected from the next list of reference surface-specific used parts, the process jumps to step S42, and the above processing is newly selected. Perform on the substrate.

S54. After the processing in step S51, a fixed set part set list is created for each mounting machine, and the processing ends.

The distribution of the remaining set-up parts is exactly the same as described above, and the subsequent processing and production are the same as already described.

An advantage of the second embodiment of the present invention is that the balance of the mounting time for each mounting machine can be improved because the fixed set components are sorted in consideration of the mounting time for each product board. .

Whether to use the first embodiment of the present invention or the second embodiment of the present invention may be in accordance with the designation of the sorting method in the line operating conditions.

Next, a third embodiment of the present invention will be described. This is also an improvement in the distribution of fixed set components, and is distributed as follows.

In the list of used parts corresponding to the production plan, parts having a large number of appearances are assigned as common parts to the part setting sections of all mounting machines except for the set-up parts setting section.

Then, the mounting machine number and the set position number are determined in consideration of the above-mentioned distribution conditions, and a used component list for each board is created in the same manner as described above. At this time, for the common parts, 0 is written in the mounting machine number to mean all mounting machines. This is shown in FIG.

Next, the mounting time of each common component and the mounting time of other components are calculated for each mounting machine.

Based on the result, a mounting machine on which the common component is mounted is determined so as not to exceed the maximum mounting time of the components other than the common component of each mounting machine.

For example, if there are two types of common parts and the mounting time is as shown in the mounting time when the common parts in FIG. No. 3, the common component 1 is mounted on the mounting machine. No. 4, the common component 2 is mounted on the mounting machine. 1 and No. If the other mounting parts are mounted on the mounting machine of No. 2, 1 to No. The loading times of the four machines were 15.5 minutes, 17.5 minutes, and 1 respectively.
At 3 minutes and 11 minutes, leveling is achieved.

In short, when a component having a large number of appearances is assigned as a common component, the degree of freedom of the channel of the fixed set component is reduced accordingly. However, since the ratio of the number of components used is high for components with a large number of appearances, it is a reality that the ratio of the number of used components is very low for components that lose channels to be set by preferentially setting common components. Therefore,
Even if a component having a low used component ratio is turned into a setup component and the setup component is sorted, the mounting time of each mounting machine can be obviously leveled as a whole.

Next, a fourth embodiment of the present invention will be described. This enables a minimum necessary setup change by issuing an instruction to set up the setup parts as described below.

A set part setting instruction is issued for a product (a plurality of products to be manufactured), and the completion information is input without delay for the manufacturing completion drawing number.

Then, when inputting the next production plan drawing number,
The above process is repeated by comparing the part drawing number required for the next production, the current set-up state of the set-up parts, and the completion state of the manufacture, and issuing an instruction for setting the minimum necessary set-up parts.

As a result, the necessary minimum setup change can be made at any time, and a production line with a short setup time and a small turn can be constructed.

Next, a fifth embodiment of the present invention will be described.

In the fifth embodiment of the present invention, the order of product introduction is improved by the following procedure to minimize the total mounting time. Here, a case where there are ten types of products will be described as an example. It is assumed that buffer stockers of about 30 printed wiring units are installed between each mounting machine.

First, the total mounting time of each product in the value mounting machine is calculated by multiplying the mounting time of each product mounting machine by the manufacturing quantity. This is shown in FIG.

Next, the order of the products is changed in the table of FIG. 19 according to the following rules.

That is, in each product, the loading machine No. The product with the longest mounting time in No. 4 is the first product. If the installed machine No. In the case where there is a product having the same mounting time among the mounting machines No. 4, 1 to No. 3 is the first one with the longer mounting time.

This is the loading machine No. which is the final loading machine.
4 is the product with the longest mounting time. This is based on the idea that if the vehicle is first introduced into the No. 4, it is not necessary for the preceding machine to wait for mounting.

In this case, the product No. 3 is the mounted machine No. 4, since the longest mounting time is 25 minutes, this is the first.

Next, the loading machine No. The product with the shortest mounting time in No. 4 is the second product.

[0205] This is because the loading machine No. Since the maximum load was applied to No.4, the next step was to mount No. 4 is loaded with the minimum load. 4 and mounted machine No. The idea is to reduce the number of printed wiring boards waiting to be mounted that accumulate between the three.

In this case, the product No. 2 is the shortest loading time 2
Product No. 2 is the second product.

At this stage, the mounting time of each mounting machine is added.

Next, in the mounting machine having the longest mounting time, the products having the shortest mounting time are arranged in the following order.

[0209] Again, the smallest load is applied next to the loaded machine with the maximum load, and at the time of the calculation of the loading time, the loading wait between the loaded machine with the maximum load and the preceding loaded machine is waited. The idea is to make it less likely to occur.

In this case, the loading machine No. No. 4 is the longest with a total mounting time of 27 minutes so far, so the product No. 4 with the shortest mounting time of 3 hours among the remaining products. 6 is selected to be the third.

Thereafter, similarly, the mounting time of each mounting machine is added, and the products having the shortest mounting time in the mounting machine having the longest mounting time are arranged in the following order.

In this way, the total mounting time for each mounting machine when the order of loading is determined is as shown in FIG. 20, and the cumulative mounting time is as shown in FIG.

As described above, according to the fifth embodiment of the present invention, the time for mounting components on all products is reduced by setting the order of product introduction while leveling the mounting time for each mounting machine. be able to.

[0214]

According to the first embodiment of the present invention, the ratio of fixed set parts and setup parts to a plurality of mounting machines is optimized, and the distribution of fixed set parts to the mounting machines is further optimized. Can be

When the production efficiency was calculated in accordance with the production plan, the operation rate of the mounted machine was about 20% in the prior art, but was reduced to 8% by applying the first embodiment of the present invention.
The operation rate was improved from 0 to 90%. This is data similar to the operation rate when mass-producing a small number of varieties.

Further, according to the second embodiment of the present invention,
Since the fixed set components are sorted in consideration of the mounting time of each product, the mounting time balance can be improved.

According to the third embodiment of the present invention,
By setting a component with a large number of appearances as a common component in the mounting machine in common, the mounting time between the mounting machines can be equalized.

Further, in the fourth embodiment of the present invention, since the set-up parts are set in consideration of the manufacturing state, it is only necessary to change the necessary minimum set-up during the manufacturing.

Finally, in the fifth embodiment of the present invention, since the product is introduced in consideration of the total mounting time of the mounting machines, the mounting time between the mounting machines can be further leveled.

[Brief description of the drawings]

FIG. 1 is a functional block diagram of a first embodiment of the present invention.

FIG. 2 is a flowchart of fixing set component determination.

FIG. 3 is an example of CAD information.

FIG. 4 is an example of component information.

FIG. 5 is an example of mounted device information.

FIG. 6 is an arrangement example of a component mounting machine in a surface mounting line.

FIG. 7 is an example of a setup part selection table.

FIG. 8 shows an example of a production plan.

FIG. 9 shows an example of line operating conditions.

FIG. 10 is an example of a used part list corresponding to a production plan.

FIG. 11 is an example of a board average for each production plan.

FIG. 12 is an example of a fixed set component / setup component distribution table.

FIG. 13 is a flowchart of a fixed set component distribution unit according to the first embodiment of the present invention.

FIG. 14 is an example of a used component list for each board according to the first embodiment of this invention.

FIG. 15 is an example of a list of used components for each board according to the second embodiment of the present invention.

FIG. 16 is a flowchart of a fixed set component distribution unit according to the second embodiment of the present invention.

FIG. 17 is an example of a list of used components for each board according to the third embodiment of the present invention.

FIG. 18 shows the mounting time when the common parts are optimally arranged.

[Fig. 19] Mounting time by mounted machine

FIG. 20 shows the mounting time of each mounting machine after the optimization of the loading order.

FIG. 21 shows the cumulative mounting time after the loading order optimization.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Central processing unit (CPU) 2 Fixed set component determination means 3 Fixed set component distribution means 4 Setup component set position determination means 5 Numerical control data (NC data) creation means 6 Surface mounting line control means 7 Loader 8 Solder printing machine 9 Adhesion Dispensing machine 10 Component mounting machine 11 Component mounting machine 12 Component mounting machine 13 Reflow furnace 14 CAD information 15 Production plan 16 Setup parts selection table 17 Parts information 18 Mounting machine information 19 Line operating conditions 20 Parts set list

Claims (5)

[Claims] The present invention relates to a production management system for a surface mounting line for mounting and soldering a surface mount component on a printed wiring board, wherein the CAD information of the printed wiring board unit, a production plan of the printed wiring board unit, and a component relating to a used component. A list of used parts corresponding to the production plan is created from the information, and a fixed set part determining means for determining a fixed set part based on a board average and a line operating condition for each production plan, and a fixed set part in the list of used parts corresponding to the production plan in order. A production management system comprising: a fixed set component distribution unit that sets the total mounting time of a mounting machine on the mounting machine having the shortest total mounting time and equalizes the total mounting time of the mounting machine. 2. The production management system according to claim 1, wherein said fixed set component distribution means includes means for uniformly distributing the mounting time of each mounting machine in the order of the number of products manufactured in the production plan. A production management system, which is a component distribution unit. 3. The manufacturing management system according to claim 1, wherein a part having a higher appearance frequency in the list of used parts corresponding to the production plan is set in common to a plurality of mounting machines as a common part. A manufacturing management system characterized by the above. 4. The manufacturing management system according to claim 1, wherein the plurality of printed wiring units being manufactured at the same time are:
A production management system, which issues an instruction to replace a set-up component based on a set-up status of a set-up component, a manufacturing completion status of a printed wiring unit, and a figure of a set-up component that needs to be set next. 5. The manufacturing management system according to claim 1, wherein the mounting of the last mounting machine is started after a printed wiring unit having the longest mounting time in the last mounting machine is initially supplied. A manufacturing management system characterized in that a printed wiring unit with the shortest time is input, and thereafter, a printed wiring unit with the shortest mounting time in a mounting machine with the longest cumulative mounting time is input.