JP2004134691A - System, method and program for component replenishment management - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a system, method, program, etc. for component replenishment management for making a circuit component mounting system efficiently perform the replenishment work of a circuit component. <P>SOLUTION: The run-out time of a component is predicted from the number of remaining circuit components, a replenishment schedule is prepared based on the predicted time, and the prepared schedule is reported to an operator. A work target time which becomes the target of replenishment work is decided based on the run-out time of the component, and the replenishment schedule can be prepared based on the time. The work target time can be set based on a replenishing form, a time necessary for the work, etc. When a congested time zone is included in the prepared schedule, the schedule can be adjusted so as to relieve congestion. Moreover, a plurality of replenishment schedules used for purposes different from each other can be prepared. <P>COPYRIGHT: (C)2004,JPO

Description

【０１０４】
部品マスターファイル１８４には、現時点で当該回路部品装着システムおいて供給されている回路部品の各々についての、部品名、その回路部品が収容されているリール４４のリールＩＤと、そのリール４４を保持しているフィーダ４２のフィーダＩＤと、そのフィーダ４２が配設されている回路部品装着機１０の装着機名およびフィーダ配設位置であるスロットＮｏ．とが互いに関連付けられて記憶されている。現時点での回路部品の残数である部品残数も、記憶項目の１つとして、この部品マスターファイル１８４に記憶されている。
【０１０５】
なお、後に説明する他の表についても同じであるが、本回路部品装着システムにおけるロータリーヘッド型回路部品装着機１０ａ，１０ｂをそれぞれＲＨ１，ＲＨ２と省略し、ＸＹロボット型回路部品装着機１０ｃ，１０ｄをそれぞれＸＹ１，ＸＹ２と省略する。スロットＮｏ．は、回路部品装着機１０ａ，１０ｂの場合、ハイフンで区切られた前の部分がデバイステーブル４６の番号を示すものとし、回路部品装着機１０ｃ，１０ｄの場合、ハイフンで区切られた前の部分が装着モジュール９４の番号を示すものとする。また、説明を単純化するために、ロータリーヘッド型回路部品装着機１０ａ，１０ｂのデバイステーブル４６の使用に関するモードは、回路部品装着機１０ａでは、前述の２テーブル連結モードを採用し、回路部品装着機１０ｂでは、前述の２テーブル交替モードを採用することとする。そして、回路部品装着機１０ｂの２つのデバイステーブル４６のうちテーブル番号２のものを予備テーブルとし、そのデバイステーブル４６に配設されているフィーダ４２から供給される回路部品に対する部品残数の管理は行わないものとする。
【０１０６】
装着作業の進行に伴い、部品残数についての供給更新処理が行われる。各回路部品装着機１０の装着機制御装置１４は、１つの回路基板に対して供給された各回路部品の供給部品数を数える供給数カウント部を有しており、１つの回路基板の装着作業が完了するごとに、スロットＮｏ．と、そのスロットＮｏ．のスロットに配設されたフィーダ４２から供給された供給部品数とを、装着システム制御装置１６に報告する。部残数管理部１８０は、その報告に基づいて、部品マスターファイル１８４の部品残数を更新する。この部品残数管理部１８０の供給更新処理によって、本部品補給管理システムは、供給されている回路部品の部品残数を常時把握しているのである。
【０１０７】
部品補給作業の際には、詳しくは補給主作業の際に、補給更新処理が行われる。各回路部品装着機１０は、装着機制御装置１４に接続された表示子読取デバイスとしてのバーコードリーダ１９０を備えており、このバーコードリーダ１９０と、装着機制御装置１４の操作パネル１９２を利用して、補給更新処理のためのデータが取得される（図２および図４参照）。前述のフィーダ交換作業の場合と、スプライシング作業の場合とでは、データの取得の方法が異なる。
【０１０８】
フィーダ交換作業においては、オペレータ１６０（前述のオペレータＡおよびＢ）は、まず部品補給を行う合図として、フィーダ交換作業を行う旨の指示と、フィーダ４２が交換されるスロットＮｏ．とを操作パネル１９２から入力する。次いで、部品切れを生じたフィーダ４２を取り外し、その後、バーコードリーダ１９０により、新たに配設するフィーダ４２のバーコードとリール４４のバーコードとを読み取る。次に、その新たなフィーダ４２を同じスロットに取り付ける。そして、交換作業の完了の旨を操作パネルから入力する。これらのデータ取得操作によって、装着機制御装置１４は、補給された回路部品に関するスロットＮｏ．、フィーダＩＤ、リールＩＤを取得し、これらの取得データを装着システム制御装置１６に送る。取得データを受け取った装着システム制御装置１６は、部品管理装置１７０から、リールＩＤをキーにして、そのリールＩＤに関連付けられているところの、そのリール４４に収容されている回路部品の部品名と、その回路部品の収容数とを受け取る。部品残数管理部１８０は、スロットＮｏ．をキーにして、フィーダ４２および部品名のチェックを行うとともに、そのスロットＮｏ．をキーにして、部品マスターファイル１８４の補給を行った回路部品の部品残数が、新たなリール４４に収容されている部品数に書き換えられる。なお、フィーダＩＤの一部分はフィーダ４２の型式を表すものとされており、フィーダチェックでは、交換前後でフィーダ４２の型式が同じか否かが判断される。
【０１０９】
スプライシング作業においては、オペレータ１６０は、まず部品補給を行う合図として、スプライシングを行う旨の指示と、スプライシングを行うフィーダ４２が配設されているスロットＮｏ．とを操作パネル１９２から入力する。次に、バーコードリーダ１９０により、新たにセットするリール４４のバーコードを読取る。スプライシング作業を行った後に、その作業の完了の旨を操作パネル１９２から入力する。これらのデータ取得操作によって、装着機制御装置１４は、補給された回路部品に関するスロットＮｏ．、リールＩＤを取得し、これらの取得データを装着システム制御装置１６に送る。取得データを受け取った装着システム制御装置１６は、部品管理装置１７０から、リールＩＤをキーにして、そのリールＩＤに関連付けられているところの、そのリール４４に収容されている回路部品の部品名と、その回路部品の収容数とを受け取る。部品残数管理部１８０は、スロットＮｏ．をキーにして、部品名のチェックを行うとともに、そのスロットＮｏ．をキーにして、部品マスターファイル１８４の補給を行った回路部品の部品残数が更新される。なお、スプライシング作業の場合は、補給時における部品残数は０になっておらず、新たなリール４４に収容されている部品数が補給時の部品残数に加算される。
【０１１０】
なお、装着作業が行われる回路基板種が変更された場合、回路部品装着機１０に対して段取替えが行われ、それに伴って、供給される回路部品およびそれに関連する構成が変更される。具体的には、フィーダ４２の配設位置の変更、フィーダ７２の付け替え等が行われる。その際に、新たに初期設定が行われ、部品マスターファイル１８４は、新たな回路基板種のものに書き換えられる。本実施形態では、説明を単純化するために、装着作業に供される回路基板種は変更されないものとして取り扱う。そのため、この初期設定については、ここでの説明を省略する。
【０１１１】
（Ｂ）部品補給管理プログラムの実行
本実施形態において実行される部品補給管理プログラムのフローチャートを図８に示す。本実施形態では、部品補給管理を行うことによって作成される補給スケジュールは、前述の補給主作業に利用される主作業スケジュールと、補給準備作業に利用される準備作業スケジュールと、部品配給作業に利用される配給作業スケジュールの３つである。部品管理プログラムの実行は任意に設定された一定時間経過ごとに行われる。本実施形態においては、１分毎に実行される。ただし、準備作業スケジュールについては５分毎に、配給作業スケジュールは１０分毎に実行されるようにプログラムにおいて設定されている。以下に、図８に示すフローチャートに従って、順次、部品補給管理の各工程を説明する。
【０１１２】
（Ｃ）部品切れ時刻予測工程
まず、ステップ１（以下、「Ｓ１」と略す。他のステップも同様とする）において、それぞれの回路部品の部品切れ時刻が予測される。装着プログラムに従って装着作業が行われる場合、１枚の回路基板に装着される各回路部品の数（以下、「装着予定部品数」という）が定まっている。具体的に言えば、どの回路部品装着機１０のどのスロットＮｏ．のスロットに配設されたフィーダ４２から供給される回路部品が、１枚の回路基板あたり何個使用されるかが、データベース部１８２の供給数量ファイル１９４（データの内容は省略）に記憶されているのである。また、回路部品装着機１０の各々の回路基板１枚あたりの装着作業時間も定まっており、この装着作業時間もデータベース部１８２に設定されて記憶されている。本実施形態においては、各ラインそれぞれのラインタクト（そのラインにおいて、電子回路が何秒毎に生産されるか）が、そのラインに配置された回路部品装着機１０の各々の装着作業時間に等しくされている。
【０１１３】
先に述べたように、部品マスターファイル１８４には、現時点での回路部品の残数が記憶されており、本ステップでは、その記憶されている回路部品の残数と、上記供給数量ファイル１９４に記憶されている装着予定部品数と、上記回路基板１枚当たりの装着作業時間とから、各回路部品の部品切れ時刻が予測される。下記表２に、各回路部品について予測された部品切れ時刻を示す。
【０１１４】
【表２】

【０１１５】
上記表２は、部品切れを生じる各回路部品にＮｏ．（以下、「部品切れＮｏ．」と呼ぶ）を付けて、部品切れ時刻の早いもの順に並べてある。また、本実施形態では、１０：００以降に部品切れが生じる回路部品を対象とし、１分刻みで部品切れ時刻を表示している。秒については、切り捨て処理がされる。つまり、例えば、１０：０２と表示されているものは、１０時０２分００秒以後１０時０３分００秒になる前に部品切れを生じる回路部品である。なお、各回路部品の部品切れ時刻は、前述したように、１分経過毎に予測される。本部品補給管理システムは、このＳ１を実行する部分として、部品切れ時刻予測部１９６（図７参照）を有している。
【０１１６】
（Ｄ）主作業スケジュール作成工程
部品切れ時刻が予測された後、続いて、Ｓ２の主作業スケジュール作成ルーチンが実行されて、補給主作業に利用される主作業スケジュールが作成される。図９に、主作業スケジュール作成ルーチンのフローチャートを示す。以下このフローチャートに従って、主作業スケジュールの作成について順に説明する。なお、主作業スケジュールの作成は、補給スケジュール作成部１９８が備える主作業スケジュール作成部２００によって実行される。補給スケジュール作成部１９８の構成については、図１０に示す機能ブロック図に示す。
【０１１７】
ｉ）補給形態設定工程
まず、Ｓ１１において、部品切れが生じる各回路部品の補給形態が設定される。本実施形態において、補給主作業に関する補給形態は、３つのものに大別される。その１つは、部品切れが発生した時点で直ちに部品補給を行う補給形態（以下、「部品切れ時補給形態」という）である。部品切れ時補給形態では、具体的には、部品切れが発生して回路部品装着機１０が停止した際に、直ちに、前述のフィーダ交換作業が行われる。別の補給形態の１つは、部品切れが発生した後設定時間経過までの間に補給主作業を行う補給形態（以下、「部品切れ後補給形態」という）である。部品切れ後補給形態は、具体的には、前述のネクストデバイスが設定されている回路部品に対するフィーダ交換作業、２テーブル交替モードが設定されている回路部品装着機１０ａ，１０ｂにおけるフィーダ交換作業とが含まれる。また、別の補給形態のもう１つは、部品切れが発生する前の設定時間内に補給主作業を行う補給形態（以下、「部品切れ前補給形態」という）である。部品切れ前補給形態は、具体的には、前述のスプライシング作業が該当する。
【０１１８】
データベース部１８２は、テーブルモードファイル２０２を有し、このテーブルモードファイル２０２には、回路部品装着機１０の装着作業に関する諸元の１つとして、各回路部品装着機１０に設定されているデバイステーブル４６，１０２の動作モード（装着機テーブルモード）が記憶されている。下記表３にその記憶内容を示す。
【０１１９】
【表３】

【０１２０】
上記表３から解るように、前述のとおり、ロータリーヘッド型の回路部品装着機１０ａ，１０ｂには、それぞれ、２テーブル連結モード，２テーブル交替モードが設定されており、ＸＹロボット型の回路部品装着機１０ｃ，１０には、１テーブル固定モードが設定されている。
【０１２１】
また、データベース部１８２は、ネクストデバイス設定ファイル２０４を有し、このネクストデバイス設定ファイル２０４には、装着作業に関する諸元、詳しくは、回路部品の供給形態に関する諸元の１つとして、スロットにネクストデバイス設定がされているか否かが、スロットＮｏ．に関連付けて記憶されている。下記表４に、その記憶内容を示す。
【０１２２】
【表４】

【０１２３】
上記表４におけるネクストデバイスの項に［ＮＤ］と表示されているスロットＮｏ．のスロットに配設されるフィーダ４２に対して、ネクストデバイスの設定がされている。一例ではあるが、表４からは、回路部品装着機１０ａの［２−０５］，［２−０６］，［２−０７］、回路部品装着機１０ｃの［１−０８］，［１−０９］、回路部品装着機１０ｄの［１−１３］，［１−１４］，［１−１５］のスロットに配設されるフィーダ４２にネクストデバイス設定がされていることが解る。なお、回路部品装着機１０ｂは、２テーブル交替モードで作動するため、いずれのスロットにもネクストデバイスの設定はなされていない。
【０１２４】
さらに、データベース部１８２は、部品諸元設定ファイル２０６を有し、この部品諸元設定ファイル２０６には、供給される回路部品に関する諸元の１つとして、各回路部品ごとに、スプライシングが可能であるか否かが、各回路部品の部品名に関連付けられて記憶されている。下記表５に、ファイルの記憶内容である各回路部品に対するスプライシング設定を示す。なお、表５に示すテーブルでは、部品保管場所の設定についても記載してあるが、これについては後述する。
【０１２５】
【表５】

【０１２６】
上記表５において、スプライシングの項に［ＳＰ］と表示されている部品名の回路部品にスプライシング設定がされている。一例ではあるが、表５からは、部品名［ＡＢＪ２１２１］，［ＡＢＪ２１２２］，［ＨＴＹ４５７８］，［ＨＴＹ４５７９］の回路部品がスプライシング可能であることが解る。なお、本実施形態では、ＸＹロボット型回路部品装着装置１０ｃ，１０ｄである限り、スプライシング設定がされている回路部品はスプライシング作業を行うこととする。
【０１２７】
各回路部品の補給形態の設定は、上記テーブルモードファイル２０２，ネクストデバイス設定ファイル２０４，部品諸元設定ファイル２０６に記憶されているデータに基づいて行われる。具体的には、部品名、装着機名、スロットＮｏ．をキーにして（表２参照）、上記３つのファイルを検索し、各回路部品が前記３つの補給形態のうちどの形態に属するかが決定される。下記表６に、ファイルの記憶内容であるところの、部品供給形態，回路部品等に関する上記諸元と部品補給形態との関連付けを示す。
【０１２８】
【表６】

【０１２９】
上記表６に従って各回路部品の補給形態が設定される。表６における「ＳＰ」はスプライシングの略称表示であり、「ＮＤ」はネクストデバイスの略称表示である。また、補給形態の項の［Ａ］は、部品切れ時補給形態を表す記号であり、［Ｂ］は、部品切れ後補給形態のうちのネクストデバイスによるものを、［Ｂ’］は、部品切れ後補給形態のうちの２テーブル交替モードによるものを、［Ｃ］は部品切れ前補給形態を、それぞれ示す記号である。以下、これらの略称表示、記号を適宜用いるものとする。
【０１３０】
下記表７に、上記補給形態設定処理の結果として、部品切れが生じる各回路部品について設定された補給形態を示す。表７から解るように、部品切れが生じる各回路部品は、各補給形態にいずれかに分類されることによって、補給形態が設定されるのである。上記説明した補給形態の設定は、補給形態設定部２０８によって実行される。
【０１３１】
【表７】

【０１３２】
ｉｉ）主作業目安時刻決定工程
続く、Ｓ１２において、前記予測された各回路部品の部品切れ時刻に基づいて、各回路部品についての補給主作業を行うための指針となる時刻、すなわち主作業目安時刻が決定される。Ｓ１２は、２つのサブステップであるＳ１３およびＳ１４を含んでおり、Ｓ１３においては、補給主作業の開始が可能なあるいは許容される時刻である主作業開始時刻が決定され、Ｓ１４においては、補給主作業を終了させなければならないあるいは終了させることが望ましいとされた時刻である主作業終了時刻が決定される。
【０１３３】
主作業開始時刻および主作業終了時刻は、上記設定された補給形態に依拠して決定される。データベース部１８２は、補給形態依拠時刻決定ファイル２１０を有し、この補給形態依拠時刻決定ファイル２１０には、下記表８にテーブル形式で示すところの、補給形態に依拠して部品切れ時刻に対して主作業開始時刻および主作業終了時刻のそれぞれを決定するために設定された開始時刻決定時間および終了時刻決定時間が記憶されている。
【０１３４】
【表８】

【０１３５】
主作業開始時刻は、部品切れ時刻に上記表８に示す開始時刻決定時間を加算して決定され、主作業終了時刻は、部品切れ時刻に上記表８に示す終了時刻決定時間を加算して決定される。部品切れ時補給形態［Ａ］の場合は、部品切れ時に直ちにフィーダ交換作業を行うため、主作業の開始される時刻および終了する時刻は部品切れ時刻と略等しく、開始時刻決定時間および終了時刻決定時間はともに０分と設定されている。ネクストデバイスによる部品切れ後補給形態［Ｂ］の場合は、部品切れ時からフィーダ交換作業が可能であり、また、部品切れ時から相当の間を経過した後であっても交換することを許容するものとして、開始時刻決定時間を０分に、終了時刻決定時間を＋５分に設定している。２テーブル交替モードによる部品切れ後補給形態［Ｂ’］の場合は、部品切れ時からフィーダ交換作業が可能であり、また、部品切れ時から比較的短い間にフィーダ交換することが望ましいため、開始時刻決定時間を０分に、終了時刻決定時間を＋２分に設定している。部品切れ前補給形態［Ｃ］では、あまり早すぎても、あまり遅すぎてもスプライシング作業が難しくなることに配慮して、部品切れ時４分〜２分の間を作業許容時間とすべく、開始時刻決定時間を−４分に、終了時刻決定時刻を−２分に設定している。
【０１３６】
下記表９に、開始時刻決定時間および終了時刻決定時間を加算して得られた各回路部品の主作業開始時刻および主作業終了時刻を、部品切れ時時刻とともに、テーブル形式で示す。
【０１３７】
【表９】

【０１３８】
上記表９において、ΔＴ１は開始時刻決定時間を、ΔＴ２は終了時刻決定時間を、Ｔ０は部品切れ時刻を、Ｔ１は主作業開始可能時刻を、Ｔ２は主作業要終了時刻を、それぞれ省略して表したものである（以下も同様に省略することがある）。また、主作業開始時刻と主作業終了時刻とに時間差がある場合、説明を単純化するために、主作業開始時刻は、その時刻において開始可能であることを意味し、例えば、１０：００の場合、１０時０分から１０時１分になるまでの間に作業を開始することが可能であることを意味するものとする。またその場合、主作業終了時刻は、その時刻になる前に終了させることを意味し、例えば１０：０２であれば、１０時１分台に終了させることを意味するものとする。上述したような処理によって主作業における目安時刻を決定するのであるが、それらの目安時刻は、主作業スケジュール作成部２００における主作業目安時刻決定部２１２によって決定され、詳しくは、作業開始目安時刻である主作業開始時刻は開始目安時刻決定部２１４によって、作業終了目安時刻である主作業終了時刻は終了目安時刻決定部２１６によって、それぞれ決定される。なお、主作業目安時刻決定部２１２は、補給形態に依拠して目安時刻を決定することから、補給形態依拠決定部２１８を有するものであるといえる。
【０１３９】
ｉｉｉ）主作業スケジュールのタイムチャート
ここで、主作業目安時刻に基づく主作業スケジュールを、タイムチャートとして、下記表１０に示す。
【０１４０】
【表１０】

【０１４１】
タイムチャートにおいて、［●］および［○］は、部品切れ時刻を示すが、［●］は、当該部品切れ時刻が属する時間帯において補給主作業が可能なことを意味し、［○］は、当該部品切れ時刻が属する時間帯において補給主作業が許容されていないことを意味する。上記表１０に示すチャートにおいては、［●］は、部品切れ時あるいは部品切れ後補給形態であると設定された回路部品の部品切れ時刻であり、［○］は、部品切れ前補給形態であると設定された回路部品の部品切れ時刻である。［−］は、当該時間帯が部品切れ時後にフィーダ交換作業な時間帯であることを示し、［＝］は、当該時間帯が、スプライシング作業が可能な時間帯であることを示している。前述の処理を経て、この表１０に示すようなスケジュール、すなわち、主作業目安時刻に基づく補給主作業に関する１つのスケジュールが作成され、Ｓ１２が終了する。
【０１４２】
ｉｖ）主作業スケジュール調整工程
上記のように主作業目安時刻に基づいて作成された主作業スケジュールに対して、次のＳ１５において、スケジュール調整が行われる。このスケジュール調整は、主作業スケジュール調整部２３０によって行われる。Ｓ１５のスケジュール調整ステップはいくつかのサブステップを含んでおり、まず、そのサブステップの１つであるＳ１６において、主作業スケジュールに過密となる時間帯である過密時間帯が存在するか否かが判断される。
【０１４３】
データベース部１８２は、主作業所要時間ファイル２３２を有しており、この主作業所要時間ファイル２３２には、下記表１１に示すところの、１つの回路部品に対する補給主作業についての標準的な所要時間である主作業所要時間が記憶されている。この主作業所要時間は、上記補給形態ごとに設定されている。
【０１４４】
【表１１】

【０１４５】
上記表１１から解るように、本実施形態では、具体的には、比較的作業時間のかかるスプライシング作業を行う部品切れ前補給形態を１分とし、フィーダ交換作業を行う部品切れ時および部品切れ後補給形態を０．５分と設定している。また、補給主作業に従事するオペレータ１６０の人員数も、データベース部１８２に設定されて記憶されている。過密時間帯の判定の基準となる時間帯はその時間幅を１分とし、ある時間帯における補給主作業の総所要時間が、上記時間幅に補給主作業に従事するオペレータ１６０の人員数を乗じた時間である時間帯内作業可能時間を超えた場合に、その時間帯を過密時間帯として認定する。本実施形態の場合、補給主作業に従事するオペレータ１６０は２人であり、時間帯内作業可能時間は２分となる。すなわち、Ｓ１６においては、補給主作業における作業所要時間とオペレータ人員数とに基づいて過密状態が判断されることになる。
【０１４６】
下記表１２に、各時間帯における補給主作業の総所要時間（調整前と表されている）を示す。なお、表１２には、スケジュール調整後の総所要時間も示されているが、これについては後に説明する。
【０１４７】
【表１２】

【０１４８】
各時間帯における総所要時間は、解りやすく言えば、表１０にチャートとして示した主作業スケジュールにおいて、ある時間帯に［●］［−］［＝］が属する場合に、それらの数と表１１に示す作業所要時間とをかけた値の総和とされる。具体的には、［●］の数×０．５＋［−］の数×０．５＋［＝］の数×１という式で求まる値が、その時間帯の総所要時間とされるのである。上記表１２から判るように、本実施形態においては、※で示す［１０：１０］，［１０：１１］，［１０：２１］の時間帯が過密状態となっている。Ｓ１６における過密時間帯の認定処理は、主作業スケジュール調整部２３０の過密時間帯認定部２３４によって実行される。
【０１４９】
次に、Ｓ１７において、上記過密時間帯が存在する場合は、その時間帯の過密状態を緩和すべく、主作業目安時刻が変更される。変更処理は、原則として、過密状態を回避する、つまり、過密状態である時間帯の総所要時間が上記時間帯内作業可能時間以内となるように行われる。その際、できるだけ早い時間帯に補給主作業が可能となることを条件として、主作業開始可能時刻あるいは主作業要終了時刻が変更される。なお、主作業開始可能時刻を後の時間帯に変更する場合は、作業可能時間が長いもの（具体的には、補給形態Ｂの回路部品）について、優先的に行われる。
【０１５０】
表１０に示したチャートを参照しつつ具体的に説明すれば、以下のようになる。時間帯［１０：１０］においては、部品切れＮｏ．［５］の回路部品についての補給主作業（表１０におけるＡ）を禁止するように、その回路部品についての主作業終了時刻が変更される。さらにその時間帯においては、部品切れＮｏ．［６］の回路部品についての補給主作業（表１０におけるＢ）を禁止するように、その回路部品についての主作業開始時刻が変更される。時間帯［１０：１１］においては、部品切れＮｏ．［１０］の回路部品についての補給主作業（表１０におけるＣ）を禁止するように、その回路部品についての主作業終了時刻が変更される。また、時間帯［１０：２１］においては、部品切れＮｏ．［１７］の回路部品についての補給主作業（表１０におけるＤ）を禁止するように、その回路部品についての主作業開始時刻が変更される。なお、Ｓ１７におけるこの主作業目安時刻の変更は、目安時刻変更部２３６によって実行される。
【０１５１】
下記表１３に、調整前および調整後の主作業開始時刻および主作業終了時刻を、部品切れ時刻と併せて示す。
【０１５２】
【表１３】

【０１５３】
上記表１３において、Ｔ１’が調整後の主作業開始時刻であり、Ｔ２’が調整後の主作業終了時刻である。※の付されている時刻が変更された時刻である。このスケジュール調整により、表１２に示すように、時間帯［１０：１０］，［１０：１１］，［１０：２１］の総所要時間が変化し、いずれの時間帯においても、補給主作業についての総所要時間は時間帯内作業可能時間以内とされて、過密状態が解消されることになる。上述のようにしてスケジュールが調整されてＳ２の主作業スケジュール作成ルーチンが終了する。なお、過密時間帯認定部２３４と主作業目安時刻変更部２３６とを含む主作業スケジュール調整部２３０は、過密状態に対応してスケジュール調整を行う過密対応調整部２３８を含むものとされているのである。
【０１５４】
（Ｅ）主作業スケジュール表示工程
Ｓ２に続いて、Ｓ３において、上記作成された主作業スケジュールが表示される。２つのラインの間には、主作業スケジュールを表示するためのコンピュータを主体とする主作業スケジュール表示装置２５０（図１，図７参照）が配置されており、主作業スケジュールは、その主作業スケジュール表示装置２５０が備えるモニタに出力されることで、オペレータ１６０に対して表示される。装着システム制御装置１６内には、当該部品補給管理システムの機能部分としてのスケジュールデータ送信部２５２（図７参照）が設けられており、その送信部２５２は、主作業目安時刻と部品切れが発生する各回路部品についての、主作業目安時刻および部品名等の部品切れ部品情報を含む主作業スケジュールデータを送信する。主作業スケジュール表示装置２５０は、そのデータを受信し、そのデータに基づいて、定められた形式の表示画面を作成してモニタに表示するのである。本部品補給管理システムにおいては、主作業スケジュール表示装置２５０は、スケジュール表示部（スケジュール報知部の一態様）として機能するのである。
【０１５５】
下記表１４に主作業スケジュール表示装置２５０に表示される主作業スケジュールを示す。主作業スケジュールは、概ね、表１４に示すような形式で表示される。
【０１５６】
【表１４】

【０１５７】
上記表１４から解るように、表示される内容は、部品切れが予測される回路部品についての部品切れ予測時刻，主作業目安時刻等が記号化されて時系列に並べられたタイムチャートと、各回路部品の部品切れＮｏ．，部品名，各回路部品を供給するフィーダ４２が配設されている装着機名およびスロットＮｏ．，ネクストデバイス設定，スプライシング設定等を含む部品切れ部品情報である。なお、表１０と比較して解るように、表１４に示す表示内容においては、表１０におけるＡ，Ｂ，Ｃ，Ｄの箇所は、過密状態を緩和すべく変更されている。補給主作業に従事するオペレータ１６０は、表示された主作業スケジュールを指針として、補給主作業を行う。きめ細かに作成されたスケジュールであるため、効率のよい部品補給を行うことができる。
【０１５８】
Ｓ３が終了した後、Ｓ４において、準備作業スケジュールの作成を行うか否かが判断される。前述したように、準備作業スケジュールは５分経過毎に行うため、先回の準備作業スケジュール作成から５分経過している場合は、Ｓ５の準備作業スケジュール作成ルーチンが実行される。５分経過していない場合は、本部品補給管理プログラムの実行は、次回の開始（約１分後）まで停止させられる。
【０１５９】
（Ｆ）準備作業スケジュール作成工程
Ｓ４において、準備作業スケジュールの作成を行うと判断された場合、Ｓ５において、準備作業スケジュール作成ルーチンが実行される。図１１に、準備作業スケジュール作成ルーチンのフローチャートを示す。以下、このフローチャートに従って、本ルーチンによる処理を説明する。なお、準備作業スケジュールの作成は、補給スケジュール作成部１９８が備える準備作業スケジュール作成部２６０によって行われる。
ｉ）準備作業所要時間設定工程
まず、Ｓ２１において、部品切れが生じる各回路部品についての、準備作業所要時間が設定される。先に説明したように、データベース部１８２が有する部品諸元設定ファイル２０６には、各回路部品について、スプライシング作業を行う部品であるか否か、その回路部品が特殊保管場所（一般の保管場所１５４以外の場所）に保管されているか否かについて設定されたデータを有している。また、データベース部１８２は、準備作業所要時間ファイル２６２を有し、この準備作業所要時間ファイル２６２には、表１５にその記憶内容を示すように、１つの回路部品に対する補給準備作業の標準的な所要時間である準備作業所要時間が設定されて記憶されている。この準備作業所要時間は、スプライシング作業であるか否かおよび特殊保管場所に保管されているか否かに関連付けられて設定されている。
【０１６０】
【表１５】

【０１６１】
表１５から解るように、特殊保管場所に保管されている回路部品の場合、準備作業を行うオペレータ１６０（前述のオペレータＣ）が自らその回路部品をその場所まで取りに行かなければならないことを考慮して、その分だけ所要時間が長く設定されている。また、補給主作業がフィーダ交換作業である場合には、補給準備作業において前述のリールセット作業を行わなければならないことから、スプライシングを行わない回路部品は、スプライシングを行う回路部品よりも所要時間が長く設定されている。各回路部品の諸元とこの設定された標準準備作業所要時間とに基づいて、部品切れを生じる各回路部品の補給準備作業の所要時間が設定される。Ｓ２１におけるこの準備作業所要時間の設定は、準備作業所要時間設定部２６４によって実行される。下記表１６に、設定された各回路部品についての準備作業所要時間を示す。
【０１６２】
【表１６】

【０１６３】
ｉｉ）準備作業目安時刻決定工程
続いて、Ｓ２２において、補給準備作業の目安となる準備作業目安時刻が決定される。Ｓ２２は、いくつかのサブステップを含んでおり、各サブステップが実行されるごとに、その実行段階に応じた準備作業目安時刻が決定され、Ｓ２２を終了した段階で、スケジュール作成の基準となる目安時刻が決定される。下記表１７に、各種準備作業目安時刻を、それらが決定される順に示す。以下、この表１７を参照しつつ説明する。
【０１６４】
【表１７】

【０１６５】
まず、Ｓ２３において、後に説明する準備作業目安時刻の基準となる目安時刻である限界時刻が決定される。限界時刻は、その時までに準備作業を終了しなければならない限界とされる時刻であり、その意味において、作業終了目安時刻の１種であるといえる。限界時刻は、前記主作業目安時刻のうちの、調整前の主作業開始時刻と調整後の主作業開始時刻とのいずれか早い時刻が限界時刻として決定される。
【０１６６】
次に、Ｓ２４において、上記限界時刻に対して余裕時間を加味して、その限界時刻を繰り上げることによって余裕加味時刻が決定される。余裕時間は、不測の事態等に考慮して、部品補給に関する作業を円滑に行うために設定された時間であり、すべての回路部品に対して一律に設定されて、データベース部１８２に記憶されている。本実施形態では、１分とされている。なお、この余裕加味時刻も、作業終了目安時刻の１種であるといえる。
【０１６７】
次いで、Ｓ２５において、Ｓ２１において設定した各回路部品についての準備作業所要時間を加味して、余裕加味時刻を繰り上げることによって、所要時間加味時刻が決定される。この所要時間加味時刻は、余裕加味時刻までに補給準備作業を終了させるためには、少なくともその時刻までには補給準備作業を開始しなければならないとされる時刻である。その意味において、所要時間加味時刻は、作業開始目安時刻の１種であるといえる。上記準備作業所要時間は、１分未満の端数を有するため、所要時間加味時刻は端数となることがあるが、その場合はさらに時刻が繰り上げられる。
【０１６８】
続くＳ２６において、各回路部品についての準備作業目安時間帯が決定される。本実施形態では、ｘｘ：００〜ｘｘ：０５，ｘｘ：０５〜ｘｘ：１０，ｘｘ１０〜ｘｘ：１５，・・・というように、５分刻みの基準時間帯が設定されており、上記所要時間加味時刻が属する時間帯が、その回路部品についての準備作業目安時間帯として決定される。この準備作業目安時間帯は、幅のある目安時刻と考えることができ、本実施形態では、この時間帯も１つの準備作業目安時刻として扱う。なお、Ｓ２３，Ｓ２４，Ｓ２６，Ｓ２７は、それぞれ、準備作業目安時刻決定部２６８が備える限界時刻決定部２６６，余裕時間依拠決定部２６８，作業所要時間依拠決定部２７０，目安時間帯決定部２７２によって実行される。これら各部を含んで、準備作業目安時刻決定部２７４が構成されているのである。
【０１６９】
ｉｉｉ）作成された準備作業スケジュール
Ｓ２２において決定された準備作業目安時刻、詳しくは、準備作業目安時間帯に基づいて、作成された準備作業スケジュールを、下記表１８に示す。表１８では、時間帯ごとに、どの回路部品についての補給準備作業を行うかが、その回路部品についての作業所要時間とともに表されている。なお、表１８には、１０：２６以降に部品切れが生じると予測される回路部品についてのデータを追加している。
【０１７０】
【表１８】

【０１７１】
ｉｖ）準備作業スケジュール調整工程
Ｓ２２を終了して作成された準備作業スケジュールは、Ｓ２７において、スケジュール調整が行われる。スケジュール調整は、準備作業スケジュール調整部２８０によって行われる。Ｓ２７はいくつかのサブステップを含んでおり、まずＳ２８において、準備作業スケジュールに過密となる時間帯が存在するか否かが判断される。その判断は、１つの時間帯に属する回路部品の作業所要時間の総和である総所要時間が、時間帯内作業可能時間を超えているか否かによって判断され、総所要時間が時間帯内作業可能時間を超える場合に、その時間帯を過密時間帯と認定する。補給準備作業に従事するオペレータ１６０の人員数はデータベース部１８２に設定されて記憶さており、その人員数に基づいて時間帯内作業可能時間が設定される。本実施形態では、従事するオペレータ１６０は１人であり、時間帯内作業可能時間は５分とされる。下記表１９に、各時間帯ごとの準備作業総所要時間を示す。なお、調整後の総所要時間をも示してあるが、これについては後に説明する。
【０１７２】
【表１９】

【０１７３】
上記表１９によれば、※印が付されている目安時間帯［１０：０５〜１０：１０］および［１０：１５〜１０：２０］において、総所要時間が時間帯内作業可能時間である５分を超え、過密状態であることが判る。これらの時間帯が過密時間帯として認定される。
【０１７４】
次に、過密時間帯が存在する場合、Ｓ２９において、その時間帯の過密状態を緩和すべく、スケジュール調整が行われる。具体的には、過密時間帯に属するいずれかの回路部品についての補給準備作業を、その時間帯の前の時間帯に前倒しさせるように調整を行う。つまり、目安時刻である準備作業目安時間帯を変更するのである。その場合、前述の所要時間加味時刻が早いものを優先的にシフトさせ、その時間帯の総所要時間が時間帯内作業可能時間より小さくなるまでの数の補給準備作業をシフトさせるのである。表１８を参照してさらに具体的に説明すれば、時間帯［１０：０５〜１０：１０］に属する部品切れＮｏ．［５］，部品名［ＪＢＧ７４１１］についての補給準備作業を［１０：００〜１０：０５］にシフトさせ、［１０：１５〜１０：２０］に属する部品切れＮｏ．［１３］，部品名［ＪＤＳ９６１４］についての補給準備作業を［１０：１０〜１０：１５］にシフトさせるのである。なお、前倒しした結果、前の時間帯が過密状態となる場合は、その時間帯について再調整を行う。原則として、すべての時間帯の過密状態が解消されるように調整される。
【０１７５】
過密状態に対応する調整の後、Ｓ３０において、作業禁止時間に対応する調整が行われる。補給準備作業には休憩時間が設定されており、その休憩時間が作業禁止時間時間として設定されている。本実施形態の場合、［１０：２０〜１０：２５］が休憩時間として設定されており、その設定された作業禁止時間はデータベース部１８２に記憶されている（表１９における◎が付された時間帯）。作業禁止時間帯に対応する調整は、その時間帯に属する回路部品についての作業をすべて、前の時間帯に前倒しさせるように行う。表１８を参照して具体的に説明すれば、部品切れＮｏ．［２１］，部品名［ＥＥＳ３５３５］および部品切れＮｏ．［２３］，部品名［ＦＤＤ４４２０］についての補給準備作業を、［１０：２０〜１０：２５］にシフトさせるのである。なお、前倒しした結果、前の時間帯が過密状態となる場合は、先の処理手順に従ってその時間帯について再調整を行う。その場合も、原則として、すべての時間帯の過密状態が解消されるように調整される。
【０１７６】
上述のようなスケジュール調整が行われて、Ｓ２７が終了し、Ｓ５の準備作業スケジュール作成ルーチンが終了する。調整上記２つの態様のスケジュール調整は、準備作業スケジュール調整部２８０が備える過密対応調整部２８２および禁止時間対応調整部２８４によって行われる。Ｓ２８およびＳ２９が過密対応調整部２８２によって実行され、Ｓ３０が禁止時間対応調整部２８４によって行われるのである。上記スケジュール調整の結果として、調整された準備作業スケジュールを、下記表２０に示す。また、表１９には、調整後の各時間帯の総所要時間が示されている。
【０１７７】
【表２０】

【０１７８】
（Ｇ）準備作業スケジュール表示工程
Ｓ５に続いて、Ｓ６において、上記作成された準備作業スケジュールが表示される。準備作業エリア１５２の近傍には、準備作業スケジュールを表示するためのコンピュータを主体とする準備作業スケジュール表示装置２９０（図１，図７参照）が配置されており、準備作業スケジュールは、その準備作業スケジュール表示装置２９０が備えるモニタに出力されることで、オペレータ１６０に対して表示される。前述のスケジュールデータ送信部２５２は、部品切れが生じると予測されれる各回路部品がについての、準備作業目安時間帯、部品名等の部品切れ部品情報を含む準備作業スケジュールデータを送信する。準備作業スケジュール表示装置２９０は、そのデータを受信し、そのデータに基づいて、定められた形式の表示画面を作成してモニタに表示するのである。準備作業スケジュール表示装置２９０も、スケジュール表示部として機能するのである。
【０１７９】
下記表２１に準備作業スケジュール表示装置２９０に表示される準備作業スケジュールを示す。準備作業スケジュールは、概ね、表２１に示すようなテーブル形式で表示される。
【０１８０】
【表２１】

【０１８１】
上記表２１から解るように、表示される内容は、部品切れが予測される回路部品についての、部品名，それが配設される装着機名，スプライシング設定，保管場所，上述の所要時間加味時刻等を含む部品切れ部品情報である。これらの部品切れ部品情報が、準備作業目安時間帯従って時間帯ごとに分類表示されているのである。なお、各時間帯において、回路部品は所要時間加味時刻の早い順に表示される。補給準備作業に従事するオペレータ１６０は、上記表示された準備作業スケジュールを指針として、補給準備作業を行う。詳しくは、原則として、１つの時間帯に属する各回路部品についての補給準備作業を、それぞれの所要時間加味時刻に間に合うように行うのである。なお、前記準備作業スケジュール表示装置２９０は、情報入力デバイスを有しており、補給準備作業が完了した旨の情報を入力することができ、この情報に基づいて、表示されている準備作業スケジュールから完了した回路部品に関する項目は削除される。また、その情報は装着システム制御装置１６に送られ、その情報に基づいて、補給準備作業が完了した回路部品は、次回の準備作業スケジュール作成の際にスケジュール作成対象から除外される。
【０１８２】
Ｓ６が終了した後、Ｓ７において、配給作業スケジュールの作成を行うか否かが判断される。前述したように、配給作業スケジュールは１０分経過ことに行うため、先回の配給作業スケジュール作成から１０分経過している場合は、Ｓ８の準備作業スケジュール作成ルーチンが実行される。１０分経過していない場合は、本部品補給管理プログラムの実行は、次回の開始（約１分後）まで停止させられる。
【０１８３】
（Ｈ）配給作業スケジュール作成工程
Ｓ７において、配給作業スケジュールの作成を行うと判断された場合、Ｓ８において、配給作業スケジュール作成ルーチンが実行される。図１２に、配給作業スケジュール作成ルーチンのフローチャートを示す。以下、このフローチャートに従って、本ルーチンによる処理を説明する。なお、配給作業スケジュールの作成は、補給スケジュール作成部１９８の配給作業スケジュール作成部２９２によって行われる。
【０１８４】
ｉ）配給作業目安時刻決定工程
まず、Ｓ４１において、部品配給作業の目安となる配給作業目安時刻が決定される。具体的には、先の準備作業スケジュール作成において決定された準備作業目安時間帯の始点となる時刻が、各回路部品の配給作業目安時刻として決定される。この時刻は、部品切れが予測される回路部品を、保管場所１５４からラインに配置された部品棚１５０まで運搬し終わっていなければならないとされる時刻であり、部品配給作業の終了の指針となる時刻である。つまり、この時刻は部品配給作業についての作業終了目安時刻としての役割を果たしている。このＳ４１は、配給作業目安時刻決定部２９４によって実行される。決定された配給作業目安時刻を、下記表２２に、テーブル形式で示す。
【０１８５】
【表２２】

【０１８６】
ｉｉ）特殊保管場所部品削除工程
続いて、Ｓ４２において、特殊保管場所に保管されている部品が、配給作業スケジュールの対象から除外される。本配給作業スケジュールは、一般部品の保管場所１５４に保管されている回路部品のみを対象としているからである。このＳ４２は、非対象部品除外部２９６によって実行される。非対象部品が削除されて配給スケジュールが作成され、Ｓ８の配給スケジュール作成ルーチンが終了する。下記、表２３に作成された配給スケジュールを示す。
【０１８７】
【表２３】

【０１８８】
（Ｉ）配給作業スケジュール表示工程
Ｓ８に続いて、Ｓ９において、上記作成された配給作業スケジュールが表示される。一般の回路部品が保管される保管場所１５４には、配給作業スケジュールを表示するためのコンピュータを主体とする配給作業スケジュール表示装置２９８（図１，図７参照）が配置されており、配給作業スケジュールは、その配給作業スケジュール表示装置２９８が備えるモニタに出力されることで、部品配給作業に従事するオペレータ１６０（前述のオペレータＤ）に対して表示される。前述のスケジュールデータ送信部２５２は、各回路部品についての部品名等の部品切れ部品情報を含む配給作業スケジュールデータを送信する。配給作業スケジュール表示装置２９８は、そのデータを受信し、そのデータに基づいて、定められた形式の表示画面を作成してモニタに表示するのである。この配給作業スケジュール表示装置２９８も、スケジュール表示部として機能するのである。配給作業スケジュールの表示形式は、上記表２３に表されている形式と同様であるため、ここでの掲載は省略する。
【０１８９】
部品配給作業に従事するオペレータ１６０は、上記表示された配給スケジュールを指針として、部品配給作業を行う。なお、前記配給作業スケジュール表示装置２９８も、情報入力デバイスを有しており、部品配給作業を終えた旨の情報を入力することができ、この情報に基づいて、表示されている配給作業スケジュールから配給し終わった回路部品は削除される。また、その情報は装着システム制御装置１６に送られ、その情報に基づいて、配給作業が完了した回路部品は、次回の配給作業スケジュール作成の際にスケジュール作成対象から除外される。Ｓ９が終了した後、本部品補給管理プログラムの実行は、次回の開始（約１分後）まで停止させられる。
【図面の簡単な説明】
【図１】本発明が適用される回路部品装着システムの全体構成を示す模式図である。
【図２】ロータリーヘッド型回路部品装着機のそれの正面側から見た斜視図である。
【図３】ロータリーヘッド型回路部品装着機のそれの背面側から見た斜視図である。
【図４】ＸＹロボット型回路部品装着機のそれの正面側から見た斜視図である。
【図５】ＸＹロボット型回路部品装着機を構成する装着モジュールの内部構造を示す斜視図である。
【図６】装着モジュールが備える装着装置を示す斜視図である。
【図７】本発明の一実施形態である部品補給管理システムの構成を示す機能ブロック図である。
【図８】本発明の一実施形態である部品補給管理プログラムのフローチャートである。
【図９】主作業スケジュール作成ルーチンのフローチャートである。
【図１０】補給スケジュール作成部の構成を示す機能ブロック図である。
【図１１】準備作業スケジュール作成ルーチンのフローチャートである。
【図１２】配給作業スケジュール作成ルーチンのフローチャートである。
【符号の説明】
１０：回路部品装着機（１０ａ，１０ｂ：ロータリーヘッド型、１０ｃ，１０ｄ：ＸＹロボット型）　１４：装着装置制御装置　１６：装着システム制御装置
４０：部品供給装置　４２：テープフィーダ（部品供給デバイス）　４４：リール　４６：デバイステーブル　１００：部品供給装置　１０２：デバイステーブル　１５０：部品棚　１５４：保管場所　１７０：部品管理装置　１８０：部品残数管理部　１８２：データベース部　１９６：部品切れ時刻予測部　１９８：補給スケジュール作成部　２００：主作業スケジュール作成部　２０８：補給形態設定部　２１２：主作業目安時刻決定部　２１４：開始目安時刻決定部　２１６：終了目安時刻決定部　２１８：補給形態依拠決定部　２３０：主作業スケジュール調整部　２３８：過密対応調整部　２５０：主作業スケジュール表示装置　２６０：準備作業スケジュール作成部　２６４：準備作業所要時間決定部
２６８：余裕時間依拠決定部　２７０：作業所要時間依拠決定部　２７２：目安時間帯決定部　２７４：準備作業目安時刻決定部　２８０：準備作業スケジュール調整部　２８２：過密対応調整部　２８４：禁止時間対応調整部　２９０：準備作業スケジュール表示装置　２９２：配給スケジュール作成部　２９４：配給作業目安時刻決定部　２９８：配給作業スケジュール表示装置[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a management system, a management method, and a management program for managing replenishment of circuit components supplied in a mounting operation of circuit components such as electronic components.
[0002]
[Prior art]
The assembly of an electronic circuit includes a component mounting operation for mounting a circuit component such as an electronic component on a surface of a circuit board, and the component mounting operation is generally performed by a circuit component mounting machine. The circuit component mounting machine is configured to include a plurality of component supply devices and a component mounting device for extracting circuit components supplied from these devices and mounting the circuit components on the surface of a circuit board. Today, when electronic circuits are mass-produced, it is desired to improve the efficiency of mounting work. One of the measures is to increase the actual operation rate of the circuit component mounting machine.
[0003]
In general, a circuit component is provided to a circuit component mounting machine as a predetermined number of aggregates (for example, in the case of an electronic component, there is a tape-shaped electronic component wound on a reel or the like). . The component supply device supplies circuit components one by one from the provided component assembly. The component assembly includes a predetermined number of circuit components, but when the components are not supplied or are lost, it is necessary to perform a replenishing operation by an operator. In many cases, various types of circuit components are supplied in the mounting operation on one circuit board. However, if even one of them is out of components, the circuit component mounting machine stops the mounting operation. This suspension of work results in a reduction in the actual operation rate of the circuit component mounting machine.
[0004]
Therefore, it has been considered to predict the time at which a component is to be exhausted and to notify the operator of this time. In connection with this, for example, Japanese Unexamined Patent Application Publication Nos. 11-232339, 2000-101291, and The technology described in Japanese Unexamined Patent Publication No. 2001-1278487 has been disclosed.
[0005]
[Patent Document 1]
JP-A-11-232339
[Patent Document 2]
JP 2000-101291 A
[Patent Document 3]
JP 2001-1278487 A
[0006]
Problems to be Solved by the Invention, Means for Solving Problems, and Effects
In each of the above-listed technologies, only the out-of-part time of each circuit component is predicted, and the predicted time is reported to the operator. Even when using these technologies, for example, when parts are concentrated at a certain time, the operator only recognizes the fact that the concentration is concentrated, and the information to be notified is based on the information. It could not be a sufficient guideline for performing avoidable replenishment tasks. In addition, the replenishment operation is divided into several operations such as an operation mainly for replenishing the circuit component mounting machine with replenishment components, and a preparation operation for the operation. For each of these divided operations, the unified information of the part exhaustion time is insufficient as information for efficient replenishment operation. Furthermore, the time required for the operation mainly for the replenishment operation or the operation for the preparation thereof differs depending on the component, and depending on the replenishment mode of the component, the time at which the replenishment operation can be performed is not the time at which the component actually runs out. In view of the difference, it is hard to say that the information of the part exhaustion time is necessarily effective. In other words, with the conventional techniques including the above-described technique, it is difficult to realize efficient replenishment of circuit components in a circuit component mounting system today, in which a large number and various types of electronic circuits are assembled in large quantities and quickly. .
[0007]
SUMMARY OF THE INVENTION It is an object of the present invention to provide a component replenishment management system, a component replenishment management method, a component replenishment management program, and the like for efficiently replenishing circuit components in a circuit component mounting system. According to the present invention, a parts supply management system, a parts supply management method, a parts supply management program, and the like in the following aspects can be obtained. As in the case of the claims, each aspect is divided into sections, each section is numbered, and the number of another section is cited as necessary. This is for the purpose of facilitating the understanding of the present invention and should not be construed as limiting the technical features and combinations thereof described in the present specification to those described in the following sections. . In addition, when a plurality of items are described in one section, the plurality of items need not always be adopted together. It is also possible to select and adopt only some items.
[0008]
In the following items, (1) corresponds to claim 1, (2) to claim 2, (7) to claim 3, (12) to claim 4, (15) is claim 5, (17) is claim 6, (23) is claim 7, (24) and (25) are claim 8, Each corresponds. Further, (31) corresponds to claim 9, and (41) corresponds to claim 10.
[0009]
(1) A plurality of component supply devices for supplying circuit components are provided and used in a circuit component mounting system including one or more circuit component mounting machines for mounting circuit components supplied from the component supply devices on a circuit board. A parts replenishment management system for managing the replenishment time of circuit parts to be performed,
A component out time predicting unit that predicts the component out time of each of the circuit components from the remaining number of each circuit component,
A replenishment schedule creating unit that creates a replenishment schedule that can be used for work related to component replenishment based on the component out time of each of the circuit components,
A replenishment schedule notification unit that notifies the operator of the replenishment schedule;
Parts supply management system including
[0010]
The parts replenishment management system of the present invention creates a parts replenishment schedule based on a part exhaustion time and notifies the operator of the schedule. In the prior art, the component shortage time is not reported as it is, but is reported in the form of a replenishment schedule, thereby providing more useful information to the operator. In other words, instead of notifying only the unprocessed data of the part outage time, it performs some processing on the data and provides the part outage information in the form of a schedule that is more useful for the operator.
[0011]
In the parts supply management system of the present invention, the supply schedule can be of various modes. More specifically, various variations of schedules can be created according to the purpose of use, replenishment timing, replenishment mode, replenishment mode, circuit component supply mode, and the like. The variations are described in detail in the following sections. explain. Further, variations other than the replenishment schedule will be described in the following sections as appropriate.
[0012]
The type of the circuit component mounting machine included in the circuit component mounting system to which the present invention is applied is not limited. For example, various types of circuit component mounting machines, such as a rotary head type circuit component mounting machine and an XY robot type circuit component mounting machine, can be managed. Further, the circuit component mounting system may be configured with only one circuit component mounting machine. In that case, the circuit component mounting machine may be used as it is as a circuit component mounting system. Conversely, the circuit component mounting system may include a plurality of circuit component mounting machines. In that case, a circuit component mounting system may be constituted by a plurality of circuit component mounting machines arranged in one electronic circuit assembly line, or a circuit component including a plurality of circuit component mounting machines extending over a plurality of lines. A mounting system may be configured. Furthermore, for example, the entire factory may be configured as one circuit component mounting system including all the circuit component mounting machines in one factory. Also, the type of the component supply device provided in the circuit component mounting machine is not limited. For example, a tape feeder for electronic component taping in which electronic components (one type of circuit components) are held on tape, a tray-type component supply device for supplying circuit components stored in a tray, and circuit components in a loose state A component supply device that handles various types of component assemblies, such as a bulk feeder that supplies components in a line, can be targeted.
[0013]
The parts supply management system may be provided anywhere. The parts supply management system desirably includes a computer as a core component thereof, and the computer may occupy most of the components. In many cases, the circuit component mounting system to be managed also includes a control device mainly composed of a computer, and the computer of the control device may also function as a computer that is the core of the component supply management system. . To put it simply, the computer of the control device of one circuit component mounting machine may be the core of the component replenishment management system, and the circuit component mounting machine may include the component replenishment management system. Also, in the case of a circuit component mounting system including a plurality of circuit component mounting machines, when a general control device that controls the system is provided, the computer of the general control device forms the core of the component replenishment management system. It may be. Different from these embodiments, a computer separate from the circuit component mounting system may be provided, and the computer may serve as a core part of the component supply management system. It should be noted that, assuming that one computer occupies the core part of the parts replenishment management system, most of the functional parts (for example, “part out of time prediction unit”, “replenishment schedule creation unit”, etc.) which are the constituent elements of the system May be provided in the computer, or each function part of the system may be provided in a distributed manner in two or more computers.
[0014]
The term “supply time” described in this section has a broad meaning of “time to perform work related to parts supply”, and “work related to parts supply” (hereinafter sometimes simply referred to as “supply work”) This means not only the operation mainly for the replenishment operation for replenishing the circuit component mounting machine, but also the preparation operation for performing the operation. The “work related to parts supply” will be described later with a specific example. The “parts-out time” which is a reference for creating a replenishment schedule may be an absolute time (for example, a time such as Japan Standard Time), such as xx hours xx minutes. A relative time may be provided such that a certain time is provided and xx minutes after the reference time. In addition, even when the part exhaustion time is predicted as a time point (for example, XX minutes XX seconds), it is predicted as a time zone having a certain time width (for example, XX minutes to XX minutes). May be performed. In this component replenishment management system, it is not always necessary to manage all the circuit components supplied in the circuit component mounting system.For example, depending on the purpose of use, only a part of them is to be managed. You can also.
[0015]
(2) The replenishment schedule creating unit includes a standard time determination unit that determines a standard operation time of each circuit component, which is a standard for performing a task related to the component replenishment, based on a component exhaustion time of each circuit component. The parts replenishment management system according to the above mode (1), wherein the replenishment schedule is created based on a reference work time of each circuit component.
[0016]
The work reference time includes a time serving as a guideline for the timing of performing the work related to parts supply. It also includes a time serving as a guide for judging when it is desirable to finish the work related to component supply for a certain circuit component and when it is desirable to start work. Various work reference times can be determined according to the purpose. The manner of the estimated work time and various aspects relating to the determination method thereof will be described in later sections. If the replenishment work is performed using the replenishment schedule created based on the estimated work time as a guide, more efficient parts replenishment can be performed. The work reference time may be determined based on certain rules, standards, methods, etc. for all the target circuit components, and may be determined for each type of circuit component, for each circuit component mounting machine, and for component supply. It may be determined by different rules, standards, methods, etc. depending on each device. In addition, a mode may be such that one work reference time is determined for one circuit component, or a plurality of work reference times may be determined. That is, a parts supply management system including a plurality of reference time determination units may be used. Furthermore, the estimated work time is determined not only directly from the part exhaustion time according to some rule or the like, but also determined once from another estimated work time and then determined according to some rule from the estimated work time. You may. The work reference time in this mode is also a time determined based on the part exhaustion time.
[0017]
(3) The reference time determination unit determines one or more of the operation reference times of the respective circuit components as a time earlier or later than the component out-of-time for each of the one or more of the circuit components. A parts supply management system according to a certain mode (2).
[0018]
In the present invention, it is not prevented that the reference work time is set to the same time as the part exhaustion time. When the time is determined as a time offset from the part exhaustion time as in the mode of this section, it is possible to create a replenishment schedule that is more suitable for the purpose of use. In addition, in addition to the mode in which the estimated working time of all the circuit components to be processed is the offset time, only some of the circuit components are determined to be early, only some are determined to be late, or It is possible to adopt various modes, such as determining a part of the time at an earlier time and another part at a later time.
[0019]
(4) In the item (2) or (3), the reference time determination unit determines one or more of the reference operation times of the circuit components as a period having a temporal width. Described parts supply management system.
[0020]
If the estimated work time is determined to be a time with a wide range in time (for example, a time zone), a replenishment schedule that is temporally flexible can be created. Here, for example, there is an advantage that flexibility is easily provided and flexibility is increased in a schedule adjustment described later. In the case of a wide period, the start time and the end time are both earlier or later than the part expiration time, and either the start time or the end time is the part expiration time. Various modes can be adopted, such as a mode in which the period is determined so that the part outage time exists between the start time and the end time. Various modes such as a mode in which the time width of the period is constant for any circuit component and a mode in which the time component varies depending on the circuit component can be adopted.
[0021]
(5) The reference time determination unit includes a start reference time determination unit that determines a reference work start time, which is a start time limit of the work related to the component supply for each circuit component. Parts supply management system described in 1.
[0022]
The estimated work start time includes, for example, the time at which the target replenishment work must be started by that time, the time at which start is requested at that time, and the time at which it is preferable to start. , Various times, such as a time at which it is possible to start. If the estimated work start time is determined in accordance with the purpose of use of the replenishment schedule, there are advantages that the use value of the replenishment schedule to be created is increased and the efficiency of the replenishment work targeted is increased.
[0023]
(6) The reference time determination unit includes an end reference time determination unit that determines a work end reference time, which is an end time of the work related to the component replenishment for each circuit component, according to any one of (2) to (5). Parts supply management system described in 1.
[0024]
Similar to the estimated work start time, the estimated work end time also includes, for example, a time at which the target replenishment work must be completed by that time, a time at which it is preferable to end the work, and a time at which the time is exceeded. Various times are included, such as times at which the work becomes difficult or impossible. As in the case of the estimated work start time, there is an advantage that the utility value of the created replenishment schedule is increased and the efficiency of the replenishment work targeted is increased.
[0025]
(7) In any one of the modes (2) to (6), the reference time determination unit includes a supply mode dependence determination unit that determines a work reference time of each circuit component based on a supply mode of each circuit component. Described parts supply management system.
[0026]
The supply form of the circuit components includes a form defined or classified according to various factors. The factors include, for example, the time when the replenishment work is possible, the time required for the replenishment work, the form of the replenishment work, the difficulty of the replenishment work, the place where the replenishment work is performed, and the like. Put simply, this circuit component is a replenishment mode in which replenishment work must be started at a time considerably earlier than the component replenishment time, or this circuit component is a replenishment configuration in which replenishment can be performed even after component depletion occurs. This means that this circuit component is in a replenishment mode in which the replenishment work takes time, and that the circuit component is in a replenishment mode in which the task of transporting the circuit component is carried away because it is far away. If the estimated work time is determined based on the supply form, the replenishment schedule created based on the estimated work time becomes a practical schedule.
[0027]
(8) The component supply management system includes a supply mode setting unit that sets a supply mode of each of the circuit components,
The part supply management system according to (7), wherein the supply form dependence determination unit determines the estimated work time of each of the circuit components based on the supply form set by the supply form setting unit.
[0028]
If the replenishment mode can be set, that is, for example, if it is determined and registered in advance for each circuit component, or if it is determined by some reference, method, or the like, it is necessary to determine the approximate work time based on the replenishment mode. Can be easily performed.
[0029]
(9) The replenishment mode setting unit performs the mounting of the circuit components on the basis of the specifications regarding the circuit component mounting machine that performs the mounting operation, the supplied circuit components, the circuit board that is used for the mounting operation, the mode of the mounting operation, and the like. The parts supply management system according to the mode (8), wherein a supply mode is set.
[0030]
The form of replenishment often depends on the various specifications described above. For example, one of the specifications of the circuit component mounting machine is that the circuit component mounting machine to which the circuit component is supplied is of a type in which the supply device is moved to supply the component. If the component supply device moves, the replenishing operation cannot be performed on the mounting machine during the mounting operation. This determines the supply mode. Also, for example, one of the specifications of the circuit component is that the circuit component is a circuit component that can be replenished (meaning “splicing” described later). If replenishment replenishment is possible, replenishment to the mounting machine can be performed before the component exhaustion time, and there is little restriction on replenishment timing. This also determines the supply mode. These are only examples of various specifications.However, it is possible to determine the replenishment type based on various specifications, and various factors or factors for determining the replenishment type. By registering the above specifications and setting the replenishment mode for each circuit component based on the specifications, the estimated working time can be more easily determined.
[0031]
(10) The replenishment schedule creation unit creates a schedule for a replenishment main task of replenishing the circuit component mounting machine with replenishment components as the component replenishment operation,
The replenishment mode setting unit sets the replenishment mode of each of the circuit components to a replenishment mode at the time of component replenishment that requires the replenishment main task when a component replenishment occurs. (8) or (9). The parts supply management system described in the section.
[0032]
The replenishment main work has a high dependency on the part exhaustion time of the work time. For example, if the replenishment mode relating to the main replenishment task is classified into the above replenishment modes in relation to the component exhaustion time, and the replenishment mode for the target circuit component is set to any of them, an efficient replenishment operation can be performed. A replenishment schedule that can perform the replenishment is created. The three supply modes described in this section will be described in detail later with specific examples.
[0033]
(11) The reference time determination unit includes a spare time dependence determination unit that determines a reference work time of each of the circuit components based on a spare time set to smoothly perform the work related to the component supply (2). A parts supply management system according to any one of the above modes (10) to (10).
[0034]
For example, a trouble may occur in one of the circuit component mounting machines, and an operator performing a component replenishing operation may perform a recovery operation. Creating a very tight replenishment schedule may not be able to respond to such contingencies. Further, even when the replenishment work is temporarily overcrowded, the tight replenishment schedule may not be able to cope with the situation. In consideration of such a situation, it is desirable to create a replenishment schedule with a certain margin. As in the mode described in this section, for example, if the estimated work time is determined in consideration of a margin time, a replenishment schedule capable of coping with the unexpected situation, overcrowding, and the like can be created. This is particularly effective in the case of a replenishment schedule that targets a replenishment operation whose operation time depends on the part exhaustion time, such as a replenishment preparation operation described later. Note that the spare time may be a uniform time for all the circuit components to be managed, or may be a different time for each circuit component depending on a supply form or the like.
[0035]
(12) The reference time determination unit includes a work required time dependence determination unit that determines a work reference time of each circuit component based on a required time of each circuit component in the work related to the component replenishment. The parts supply management system according to any one of the above modes (11).
[0036]
For example, the time at which the target replenishment operation must be started depends on the required operation time of the replenishment operation. If the estimated work time is determined in consideration of the required work time, it is possible to create a replenishment schedule more suited to the actual state of the replenishment work.
[0037]
(13) The parts replenishment management system includes a required time setting unit that sets a required time for each circuit component for each circuit component.
The part replenishment management system according to (12), wherein the work required time dependency determination unit determines the estimated work time of each of the circuit components based on the required work time set by the required time setting unit.
[0038]
If the required work time can be set, that is, for example, if it is determined and registered in advance for each circuit component, or if it is determined by some reference, method, or the like, the estimated work time is determined based on the required work time Can be easily performed.
[0039]
(14) The required time setting unit is configured to perform each of the circuit components on the basis of the specifications regarding the circuit component mounting machine that performs the mounting operation, the supplied circuit components, the circuit board that is used for the mounting operation, and the form of the mounting operation. The part replenishment management system according to the mode (13), wherein the required operation time is set.
[0040]
The required working time often depends on the above various parameters. The specifications are the same as those described above, and the description is omitted here. It is possible to determine the required work time based on various specifications, and the above-described specifications as various factors or elements for determining the required work time are registered and the like, and based on the specifications. By setting the required work time for each circuit component, the estimated work time can be more easily determined.
[0041]
(15) The replenishment schedule preparation unit includes a schedule adjustment unit that, when it is determined that the replenishment schedule to be prepared needs adjustment, adjusts the replenishment schedule according to a predetermined adjustment condition. A parts supply management system according to any one of the above modes (14) to (14).
[0042]
The mode described in this section is a particularly effective mode when the replenishment operation according to the prepared replenishment schedule is, for example, impossible or inefficient in a part thereof. The case where it is determined that adjustment is required and the conditions for adjustment will be described later with specific examples.
[0043]
(16) The replenishment schedule creating unit includes a standard time determining unit that determines a standard operation time of each circuit component as a standard for performing a task related to the component replenishment based on a component out time of each circuit component. The replenishment schedule is created based on the reference work time of each circuit component,
The parts replenishment management system according to (15), wherein the schedule adjustment unit adjusts the schedule by changing at least one of the estimated working times of the circuit components.
[0044]
When the replenishment schedule is created based on the estimated work time, the schedule can be easily adjusted by changing the estimated work time for each circuit component. For example, a case in which the replenishment schedule is adjusted so that replenishment work is started quickly by changing the estimated work time of some circuit components to an earlier time is included in the aspect of this section.
[0045]
(17) When the schedule adjustment unit determines that there is an overcrowded time zone in which the work related to the component replenishment according to the created replenishment schedule is overcrowded, the schedule adjustment unit adjusts the schedule to reduce the overcrowded state. The parts supply management system according to the above mode (15) or (16), further comprising a corresponding adjustment unit.
[0046]
When there is a time zone where the schedule is overcrowded, this is one mode in which schedule adjustment is required. In the overcrowded time zone, there is a possibility that the efficiency of the mounting operation is reduced due to a stoppage of the circuit component mounting machine due to a failure to supply components in time. In such a case, under the adjustment condition of mitigating the overcrowding state, for example, in the aspect described in this section in which the replenishment work load is leveled, it is necessary to create a replenishment schedule that ensures more efficient replenishment work. Is possible.
[0047]
(18) The overcrowding correspondence adjustment unit determines the presence or absence of the overcrowding time zone based on the required work time of the work related to the component supply for each circuit component, and adjusts the schedule. Parts supply management system described in 1.
[0048]
When judging whether or not it is in an overcrowded time zone, for example, the overcrowded state is simply determined by the number of circuit components in which the component runs out in that time zone, or the number of circuit components for which the estimated working time exists in that time zone. Judgment is also possible. In the mode described in this section, the overcrowded state is determined based on the time required for the replenishment operation, so that a more accurate determination can be made.
[0049]
(19) The overcrowding correspondence adjustment unit determines the presence or absence of the overcrowding time zone based on the number of operators engaged in the work related to the parts supply and adjusts the schedule (17) or (17). Item 18).
[0050]
Whether it is in an overcrowded state depends on the number of operators engaged in replenishment work. Even if the parts are out of the same state, if there are many operators, it will not be overcrowded, and if there are few operators, it will be overcrowded. Therefore, as in the embodiment described in this section, the overcrowded state can be determined more accurately based on the number of operators. It should be noted that the number of personnel may be constant for any time zone, or the number of operators may be changed according to the time zone.
[0051]
(20) When the schedule adjustment unit determines that a part of the work related to the component replenishment according to the created replenishment schedule is to be performed in the work prohibited time zone, to avoid the work in the work prohibited time zone. The parts replenishment management system according to any one of the above modes (15) to (19), further comprising a prohibition time corresponding adjustment unit for performing schedule adjustment.
[0052]
The schedule in which the replenishment work must be performed during the work prohibition time zone is one mode in which the schedule needs to be adjusted. For example, when a time period during which a break time is set for the operator, or when a time period during which the operator performing replenishment work is required to engage in other work such as maintenance is set, etc. Is the work prohibited time zone. The mode described in this section is a mode in which the schedule is adjusted under the adjustment condition that the work is not performed during the working hours, and the replenishment schedule can be created in accordance with the actual work contents and work form of the operator. .
[0053]
(21) The replenishment schedule creation section is a main work schedule creation section that creates a main work schedule that can be used for a replenishment main work for replenishing the circuit component mounting machine with replenishment parts (1) to (20). The parts supply management system according to any one of the above.
[0054]
As will be described later using a specific example, the main replenishment operation is an operation mainly performed by the replenishing operation performed on the circuit component mounting machine. The timing at which the replenishment operation is performed is highly dependent on the component exhaustion time. Therefore, the replenishment schedule for the replenishment main work has a merit of minimizing the stoppage of the operation of the circuit component mounting machine, and is a highly useful replenishment schedule.
[0055]
(22) The replenishment schedule creation unit is a preparation work schedule creation unit that creates a preparation work schedule that can be used for replenishment preparation work for preparing replenishment parts before the circuit component mounting machine can be replenished. And a parts supply management system according to any one of (20) to (20).
[0056]
As will be described later with reference to a specific example, the replenishment preparation work for performing the replenishment main work has a relatively small dependence on the part exhaustion time when the work is performed. Therefore, for example, if the work is leveled, efficient work can be performed with a small number of operators. Therefore, the replenishment schedule for the replenishment preparation work is a highly useful schedule for performing efficient work.
[0057]
(23) The parts replenishment management system includes a plurality of the replenishment schedule creation units, and the plurality of replenishment schedule creation units creates each of a plurality of replenishment schedules having different usage purposes. (20) The parts supply management system according to any one of the above (20).
[0058]
For example, there are various replenishment schedules such as a schedule for minimizing the stoppage of the operation of the circuit component mounting machine and a schedule for replenishing components with a small number of personnel. If the replenishment work is managed by a plurality of replenishment schedules having different utilization purposes, more efficient replenishment work can be realized.
[0059]
(24) The parts replenishment management system according to the mode (23), wherein each of the plurality of replenishment schedule creation units creates the replenishment schedules in which operations related to the target part supply are different from each other.
[0060]
The schedule for each type of target replenishment work is also one aspect of the replenishment schedule for different purposes. If a plurality of replenishment schedules for different replenishment operations are created and, for example, each replenishment schedule is used as a guideline for each replenishment operation, more efficient component replenishment is realized.
[0061]
(25) The plurality of replenishment schedule creation units, a main work schedule creation unit that creates a main work schedule that can be used for a replenishment main work for replenishing the circuit component placement machine with replenishment parts, and replenishment to the circuit component placement machine The part supply management system according to item (24), including at least one of a preparation work schedule creation unit that creates a preparation work schedule that can be used for a supply preparation work that prepares a supply part to the extent possible.
[0062]
As described above, each of the supply main operation and the supply preparation operation is a certain practical division operation in the supply operation. If a plurality of replenishment schedules including a schedule for any of these practical sorting tasks is created, parts replenishment can be performed efficiently.
[0063]
(26) The parts supply management system according to (25), wherein the plurality of supply schedule creation units include both the main work schedule creation unit and the preparation work schedule creation unit.
[0064]
For example, the replenishment main work and the replenishment preparation work differ in the degree of dependence of the work time of the work on the part exhaustion time. If two replenishment schedules are created for each of the two replenishment operations having different characteristics, parts replenishment can be performed more efficiently.
[0065]
(27) The replenishment schedule creating unit includes a standard time determining unit that determines a standard operation time of each circuit component as a standard for performing a work related to the component replenishment based on a component out time of each of the circuit components. The replenishment schedule is created based on the reference work time of each circuit component,
The replenishment schedule notifying unit includes, as the replenishment schedule, a schedule display unit that displays out-of-parts information, which is information on each circuit component whose occurrence of out-of-parts is predicted, in association with a reference work time of each of the circuit components. The parts supply management system according to any one of the above modes (1) to (26).
[0066]
Various means, such as a visual means and an audible means, can be used to notify the operator of the replenishment schedule. For example, the schedule notification unit in the present invention, such as notification using a warning light such as a patrol light or notification using sound, can employ various notification means. The work reference time is information that is highly used in parts supply work. If the part-out part information associated with the work reference time is displayed, the information becomes useful information for the operator using the schedule. For example, various display formats can be adopted, such as displaying component out-of-component information in a table format by arranging the component out-of-order information in the order of the estimated work time, or displaying the schedule in a chart format so that the operator can easily grasp the schedule.
[0067]
(28) The schedule display unit stores, as the part-out part information, a part name of each circuit part whose occurrence of the part-out is predicted, a device name of each part supply device in which each circuit part is stored, and The component replenishment management system according to mode (27), wherein one or more pieces of information selected from an arrangement position of the component supply device and a mounting machine name of a circuit component mounting machine to which the circuit component is replenished are displayed.
[0068]
There is no particular limitation on the contents of the out-of-parts information, in other words, what is displayed as the out-of-parts information, and various information can be displayed according to the purpose of use of the schedule. Any of the above-listed information can be useful information for the parts supply operation, and the supply schedule displayed including such information is a practical schedule.
[0069]
(29) The component out-of-time predicting unit may calculate each of the circuits based on the number of circuit components mounted per circuit board to be mounted and the time required for mounting one circuit board. The parts replenishment management system according to any one of the above modes (1) to (28), which predicts the time at which a part will run out.
[0070]
Mounting work by a circuit component mounting machine is often determined by a mounting program, and the number of circuit components mounted on one circuit board and the time required for mounting work on one circuit board depend on the circuit board. It can be easily grasped by the mounting program. For example, the system always keeps track of the current time, and based on the number of circuit components and the time required for the mounting operation, for example, every time mounting operation on one circuit board is completed, the number of remaining components is calculated based on the number of remaining components. Can be predicted by calculation.
[0071]
(31) A circuit component mounting system in which a plurality of component supplying devices for supplying circuit components are provided and at least one circuit component mounting machine for mounting a circuit component supplied from the component supplying device on a circuit board is provided. A parts supply management method for managing the supply time of circuit parts to be supplied,
A component outage time prediction step of predicting the component outage time of each circuit component from the remaining number of each circuit component,
A replenishment schedule creating step of creating a replenishment schedule that can be used for work related to component replenishment based on the component out-of-time of each circuit component,
A replenishment schedule notifying step of notifying the operator of the replenishment schedule;
Parts supply management method including
[0072]
According to the parts supply management method of the present invention, as described with reference to the description of the parts management system of the present invention, it is possible to provide out-of-part information in a more useful form. . The parts replenishment management method according to the present invention is implemented in a mode in which the parts replenishment management method described in this section is further limited by the technical features described in any of the above-mentioned paragraphs (2) to (29). can do. Since the similar description is repeated, the description of those aspects is omitted.
[0073]
(41) A circuit component mounting system in which a plurality of component supply devices for supplying circuit components are provided and at least one circuit component mounting machine for mounting a circuit component supplied from the component supply device on a circuit board is provided. A part supply management program executed by a computer to manage a supply time of circuit parts to be supplied,
A component outage time prediction step of predicting a component outage time of each of the circuit components from the remaining number of each circuit component,
A replenishment schedule creating step of creating a replenishment schedule that can be used for work related to component replenishment based on the component out-of-time of each of the circuit components,
A replenishment schedule notifying step of notifying the operator of the replenishment schedule;
Parts supply management program including
[0074]
By executing the parts supply management program of the present invention, it is possible to provide out-of-parts information in a more useful form, as understood with reference to the description provided for the parts management system of the present invention. It is. The parts replenishment management program according to the present invention is a part replenishment management program according to any one of the above-described items (2) to (29), with the technical features described in any one of the above items (2) to (29) added thereto. can do. Since the similar description is repeated, the description of those aspects is omitted.
[0075]
(42) A recording medium on which the program according to (41) is recorded so as to be readable by a computer.
[0076]
The recording medium described in this section relates to a storage medium in which the program of (41) is stored, and the stored program is the technical feature described in any of the above-mentioned paragraphs (2) to (29). Can be programmed. Since the similar description is repeated, the description of those aspects is omitted.
[0077]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment of the present invention will be described in detail. However, the present invention is by no means limited to the following embodiments. In addition to the following embodiments, the aspects described in the section [Problems to be Solved by the Invention, Problem Solving Means and Effects] can be used. First, the present invention can be implemented in various forms with various changes and improvements based on the knowledge of those skilled in the art.
[0078]
<Circuit component mounting system>
(A) Overall configuration of circuit component mounting system
FIG. 1 schematically shows the overall configuration of a circuit component mounting system to which the present invention is applied. The circuit component mounting system includes a part of each of two electronic circuit assembly lines. Each of the two electronic circuit assembly lines has a circuit component assembly line as a main board-to-board working machine, a solder printing machine for printing cream solder on a circuit board (a printed wiring board, etc.), and a circuit component for a circuit board. An adhesive application machine for applying adhesive for fixing, two circuit component mounting machines for mounting circuit components on a circuit board, and a reflow furnace for soldering are provided. Out of it. It is configured to include the circuit component mounting machine 10 among the board working machines that perform various board workings on the circuit board. In the figure, two circuit component mounting machines 10 of each line among the board working machines are described. The circuit component mounting machines 10 are rotary head type mounting machines 10a, 10b provided on the upstream side and XY robot type mounting machines 10c, 10d provided on the downstream side. The rotary head type mounting machines 10a, 10b are As high-speed mounting machines for mounting relatively small circuit components at high speed, XY robot-type mounting machines 10c and 10d are provided as general-purpose mounting machines for mounting relatively large or odd-shaped circuit components. The board working machines of each line are connected by a conveyor 12 as a board transport device, and the circuit board is carried from the upstream side to the downstream side, and predetermined board working is performed by each board working machine in sequence. The assembly of the electronic circuit is completed.
[0079]
As described above, this circuit component mounting system is configured to include the four circuit component mounting machines 10 described above. Each of these circuit component mounting machines 10 includes a mounting machine control device 14 (each of which may be referred to as 14a, 14b, 14c, or 14d corresponding to the circuit component mounting machine) that controls each of them mainly by a computer. Each of these mounting machine control devices 14 is connected to a mounting system control device 16 that controls the entire circuit component mounting system mainly by a computer. That is, the four circuit component mounting machines 10 are placed under the overall control of the mounting system control device 16 (not shown, but the other board working machines are also controlled by the mounting system control device 16 as well. It is placed in). The type, order, quantity, etc. of the circuit boards to be used for the work are grasped by the mounting system control device 16 as a production plan. The control of the transfer of the circuit board and the like are also performed by the mounting system control device 16, and the circuit component mounting machine 10 performs the work based on the instruction of the mounting system control device 16. As can be seen from FIG. 1, the rotary head type circuit component mounting machines 10a, 10b and the XY robot type mounting machines 10c, 10d are arranged facing each other.
[0080]
(B) Configuration of rotary head type circuit component mounting machine
FIG. 2 is a perspective view from the front side of the rotary head type circuit component mounting machines 10a and 10b, and FIG. 3 is a perspective view from the back side. Since the circuit component mounting machine 10a and the circuit component mounting machine 10b have the same configuration, the following description will be made only for the circuit component mounting machine 10a. The circuit component mounting machine 10a includes a mounting machine body 30 and the above-described mounting machine control device 14a. In addition, in the figure, the mounting machine main body 30 is shown with the exterior plate removed. The mounting machine main body 30 includes a skeleton portion 36 having a base 32 and a frame 34 provided on the base 32, and has a structure in which various functional portions are disposed on the skeleton portion 36. A mounting device 38 is provided at a central portion of the frame 34.
[0081]
A component supply device 40 capable of disposing a plurality of component supply devices is provided at a front portion on the base 32. For simplicity of description, in the present embodiment, only the tape feeder 42 (hereinafter abbreviated as “feeder 42”) is handled as the component supply device. The feeder 42 is an electronic component taping (a type of component assembly, hereinafter referred to as “taping”), which is a taped electronic component (a type of circuit component; hereinafter, generically referred to as “circuit component”). The reel 44 (which is a kind of component assembly housing member) is wound around the reel 44, and taping extending from the reel 44 is sent out at a predetermined pitch, and the circuit components are supplied one by one at a predetermined position. Is what you do. The feeder 42 is configured to supply circuit components one by one at a predetermined component removal position by pressing a feed lever provided therein by a rod provided on the mounting device 38 side. The feeder 42 has a well-known structure, and a description thereof will be omitted.
[0082]
The component supply device 40 has two device tables 46 for arranging and arranging the feeders 42, and each of the device tables 46 is provided with a plurality of slots for mounting the respective feeders 42. The feeder 42 is attached to any of the plurality of slots, so that the feeder 42 is disposed at a predetermined position of the component supply device 40. Each of the two device tables 46 is moved in the left and right direction by a table moving device 48. FIG. 2 shows a state in which the feeder 42 is attached to only one of the device tables 46. In the one device table 46 as well, the feeders 42 other than the feeders 42 attached to both ends are omitted. I have.
[0083]
In the upper portion on the rear side of the base 32, three conveyors 60a, 60b, and 60c are provided as substrate transfer devices in the circuit component mounting machine 10a. In the circuit component mounting machine 10a, in order to transfer the circuit board from the left (the right in FIG. 3) to the right (the left in FIG. 3), the conveyor 60a disposed on the upstream side includes the in-side conveyor, The conveyor 60c arranged on the downstream side functions as an out-side conveyor (in the circuit component mounting machine 10b, the board transport direction is opposite, so the opposite). In addition, a substrate holding device 62 is provided at the upper center of the base 32. Although a detailed description of the structure is omitted, the board holding device 62 fixes and holds the circuit board to be mounted on the board holding unit, functions as an XY table itself, and holds the circuit board. It is possible to move within one plane as it is.
[0084]
The mounting device 38 includes a mounting head 66 having a plurality of mounting units 64 arranged on one circumference, and a head driving device 68 for driving the mounting head 66. Although a detailed description is omitted, the mounting unit 64 includes a suction nozzle (one type of a component holding device) that suctions and holds a circuit component at a negative pressure at a lower portion thereof. The mounting unit 64 is intermittently rotated in one direction by the head driving device 68, descends at a foremost stop position (a component extraction station), and takes out circuit components supplied from the component supply device 40. It descends at a stop position (component mounting station) on the rear side, and mounts its own circuit components on the surface of the circuit board held by the board holding device 62.
[0085]
The component mounting operation by the circuit component mounting machine 10a is performed as follows. First, the circuit board is carried into the central conveyor 50b from outside the machine by the in-side conveyor 60a. The board holding unit of the board holding device 62 moves to the transfer position, at which position the circuit board is transferred, and the board holding unit holds the transferred circuit board and then moves to the mounting work position. The mounting of the circuit components is performed according to a mounting program for the circuit board. The component supply device 40 sequentially moves the device table 46 such that the component removal position of the feeder 42 that stores the circuit components to be supplied is positioned at the component removal station in the order in which the components are to be mounted. The mounting unit 64 sequentially positioned at the component take-out station due to the intermittent rotation of the mounting head 66 sucks and holds sequentially supplied circuit components at the suction nozzle. The mounting unit 64, which is intermittently rotated and located at the sequential component mounting station, mounts the circuit components held by the mounting unit 64 on the surface of the circuit board located at the mounting operation position. At this time, the circuit board is moved to a predetermined position of the board holding unit of the board holding device in accordance with the mounting timing. By these operations, predetermined circuit components are mounted at predetermined positions on the surface of the circuit board in a predetermined order. After the mounting is completed, the board holding unit moves to the transfer position, the circuit board is transferred to the central conveyor 50b, and is carried out of the apparatus by the out-side conveyor 50c.
[0086]
In the circuit component mounting apparatus 10a, the two device tables 46 are moved to supply components. Two modes are set for the usage modes of these two device tables 46. One of them is a “two-table replacement mode”, in which all of the feeders 42 that supply circuit components mounted on one circuit board are arranged in the respective device tables 46, and the work of mounting one circuit board is performed. , In which only one of them is used alone. The “two-table replacement mode” can be further classified into various usage modes. However, in the present embodiment, in order to simplify the description, the feeder 42 provided in one device table 46 is mainly used, and one of the two is used. Only when one of the feeders 42 arranged in the device table 46 of the first device table 46 has run out of parts, the feeder 42 is replaced with the other device table 46 and the feeder 42 arranged in the other device table 46 is replaced. To supply circuit components. That is, in this mode, one device table 46 is set as a “main table” and the other device table 46 is set as a “spare table”. When parts are replenished to the feeder 42 of the main table 46 where the parts have run out, the supply is immediately switched to the supply from the main table 46. This is a usage mode in which the stop of the mounting operation can be suppressed as much as possible when parts run out. The other mode is a “two-table connection mode” in which a feeder 42 for supplying a circuit component mounted on one circuit board is divided into both of two device tables 46, and two device tables 46 are provided. In this mode, components are supplied as if they were integrated, that is, as if they were connected. This is an advantageous mode when there are many types of circuit components mounted on one circuit board.
[0087]
(C) Configuration of XY robot type circuit component mounting machine
FIG. 4 is a perspective view from the front side of the XY robot type circuit component mounting machines 10c and 10d, FIG. 5 is a perspective view of the inside of the mounting module constituting the circuit component mounting machine, and FIG. 6 is shown in FIG. Since the circuit component placement machine 10c and the circuit component placement machine 10d have the same configuration, the following description will be made only for the circuit component placement machine 10c. The circuit component mounting machine 10c includes a mounting machine main body 90 and the above-described mounting machine control device 14c. The mounting machine main body 90 is configured to include a base module 92 and four mounting modules 94 provided on the base module 92 so as to be aligned in the board transfer direction. The mounting module 94 is configured by arranging various functional portions on a module frame 96, and each of the mounting modules 94 can function as a mounting machine.
[0088]
Each of the mounting modules 94 is provided with a component supply device 100 at a front portion thereof as one of functional parts, in which a plurality of component supply devices can be arranged. As in the case of the rotary head type circuit component mounting machines 10a and 10b, only the feeder 42 is handled as the component supply device. As described above, the feeder 42 holds the reel 44 on which the taping is wound, sends out the taping extending from the reel 44 at a predetermined pitch, and supplies the circuit components one by one at a predetermined position. However, the feeder 42 used in the XY robot type circuit component mounting machine 10c is different from the above-described one in that the feeder 42 has an electric motor as a drive source, and is driven in accordance with a signal from the mounting machine control device 14c. Is designed to supply circuit components one by one. The feeder 42 also has a well-known structure, and a description thereof will be omitted.
[0089]
The component supply device 100 has a device table 102 for arranging and arranging the feeders 42, and the device table 102 is provided with a plurality of slots for mounting the respective feeders 42. The feeder 42 is disposed at a predetermined position in the component supply device 100 by being attached to any of the plurality of slots. In the XY robot type circuit component mounting machine 10c, unlike the case of the rotary head type circuit component mounting machines 10a and 10b, the device table 102 does not move and the position thereof is fixed.
[0090]
The mounting module 94 includes, as another functional part, a substrate transport device 104 that plays a role of transporting the substrate in the mounting machine. The board transfer device 104 is a device mainly including a conveyor, and cooperates with the board transfer device 104 of the adjacent mounting module 94 to transfer the circuit board in the left and right direction, which is the board transfer direction, and perform component mounting work. And performs a role of fixing and holding the circuit board at a mounting operation position which is a position for performing the operation. The substrate transport device 104 has two conveyors before and after, and functions as a two-line transport device. It should be noted that it can also function as a one-line transport device, and for simplicity of description, will be treated as a one-line transport device in the following description.
[0091]
The mounting module 94 has a mounting device 110 provided on the beam section 106 of the module frame 96. The mounting device 110 includes a mounting head 112 and a head moving device 114 that moves the mounting head 112 over the component supply device 100 and the substrate transfer device 104 in one plane. The head moving device 114 is provided on the beam unit 106 and moves the Y slide 116 in the Y direction perpendicular to the substrate transport direction. The head moving device 114 is provided on the Y slide 116 and moves the mounting head 112 in the substrate transport direction. An X-direction moving device 120 for moving in a certain X direction is provided, and is configured as an XY robot type moving device. Although a detailed description is omitted, the mounting head 112 includes a plurality of mounting units 122 that are arranged on one circumference with a suction nozzle as a component holding device at a lower portion, and the mounting units 122 are intermittent. Rotated. Each of the mounting units 122 is sequentially lowered when it is sequentially positioned at a predetermined stop position, ie, a take-out / mounting station, so that the circuit components are sucked and held or the held circuit components are mounted on the surface of the circuit board.
[0092]
The component mounting operation by one mounting module 94 is performed as follows. First, the circuit board is loaded into the mounting module 94 by the board transfer device 104 of the mounting module 94 while cooperating with the conveyor 12 or the board transfer device 104 of the mounting module 94 arranged upstream. It is fixed and held at a predetermined mounting work position. The mounting of the circuit components is performed according to a mounting program for the circuit board. The mounting head 112 moves to a predetermined position above the component supply device 100 while intermittently rotating the mounting unit 122 according to the mounting order, and sequentially takes out circuit components from the mounting unit 122 located at the pick-up / mounting station. Next, the mounting head 112 moves above the component imaging device 124 provided between the component supply device 100 and the substrate transport device 104, and the circuit component sucked and held by the component imaging device 124 is imaged. This imaging is performed to acquire a component holding position error, but a detailed description thereof is omitted. Subsequently, the mounting head 112 moves to a predetermined position above the substrate transfer device 104 while intermittently rotating the mounting unit 122 according to the mounting order, and is sequentially held by the mounting unit 122 located at the unloading / mounting station. The circuit component is mounted on the surface of the circuit board fixed at the mounting position. The above-described component removal and component mounting operations are repeated as necessary, and mounting on one circuit board is completed. In this way, on the surface of the circuit board, the predetermined circuit components are mounted at the predetermined positions in the predetermined order. After the mounting is completed, the circuit board is released from being fixed, and the circuit board is unloaded from the mounting module 94 in cooperation with the substrate transport device 104 of the downstream mounting module 94 or the downstream conveyor 12. The mounting operation of one circuit board by the circuit component mounting machine 10c is completed by performing the operation of the one mounting module 94 for all the mounting modules 94 from the upstream side to the downstream side.
[0093]
<Parts exhaustion and replenishment work>
In the above-described circuit component mounting system, when a circuit component held by any of the feeders 42 provided in each circuit component mounting machine 10 has a component cut, in principle, the feeder 42 in which the component cut has occurred is The work operation of the disposed circuit component mounting machine 10 stops at that time. Therefore, when a component runs out, it is necessary to replenish the component immediately, and if possible, it is desirable to replenish the component before the component runs out.
[0094]
Even when parts run out, it is possible not to stop the work operation at that time. One aspect is that the same circuit component can be supplied from a plurality of feeders 42 in one circuit component mounting machine 10, and is always supplied from one feeder 42. This is a component supply mode in which the feeder 42 to be supplied is switched. Such a supply mode will be referred to as a “next device”. Another aspect is the “two-table replacement mode” in the rotary head type circuit component mounting apparatuses 10a and 10b described above. In the present embodiment, the “next device” is used for some of the feeders 42, and the “two-table replacement mode” is used for some of the circuit component mounting apparatuses 10. Even in the case of employing these component supply modes, in the “next device”, when the components run out in all the feeders 42 set with the next device, the work operation stops, and the “2 table replacement” is performed. In the "mode", the work operation is stopped when the feeder 42 arranged on the spare table is out of parts. Therefore, even when these supply modes are employed, it is desirable to replenish components as quickly as possible when a component runs out.
[0095]
In the rotary head type circuit component mounting machines 10a and 10b, the operation of replenishing the circuit components in which the next device is set is stopped when the circuit board used for the mounting operation is switched. In the case of the XY robot type circuit component mounting machines 10c and 10d, since the device table 102 does not move, the replenishment operation can be performed without stopping the operation. In the case of the two-table replacement mode, components are supplied by the feeder 42 disposed on the spare table 46, and the main table 46 is stopped. It is possible.
[0096]
Separately from the above-described supply mode, a method of adding taping can be adopted as component replenishment before component shortage occurs. The reel 44 is detached from the feeder 42 where parts are likely to run out, and the end of the taping unwound from the reel 44 and the leading end of the taping wound on a new reel 44 prepared in advance are connected. The new reel 44 is set in the feeder 42. Parts supply using this method is called "splicing". Since the splicing cannot be performed when the table moves, and cannot be performed depending on the circuit components, in the present embodiment, the circuits supplied in the XY robot type circuit component mounting machines 10c and 10d are used. It shall be adopted in some parts.
[0097]
In the present embodiment, the work related to parts supply can be distinguished into three partial works. One of the operations is an operation of replenishing circuit components to the circuit component mounting machine 10, or, more generally, an operation of setting circuit components in the component supply devices 40 and 100 of the circuit component mounting machine 10. This operation is called “supply main operation”. In the present embodiment, for the sake of simplicity, the main supply operation is assumed to be performed in two modes. One of them is a work of exchanging the feeder 42 holding the reels 44 wound with a sufficient amount of taping with a feeder in which parts are broken, that is, a work of exchanging the so-called feeder 42 (feeder exchanging work). The other is an operation for performing the above-described splicing (splicing operation). Although it is conceivable to replace only the reel 44 with the feeder 42 remaining in the component supply device 42, this is a time-consuming operation, and will not be adopted in this embodiment.
[0098]
The other of the three partial operations in the operation related to parts supply is a preparation operation for performing the main supply operation. This operation is called “supply preparation operation”. In the present embodiment, the replenishment preparation work assumes only two forms of work. One of them is a feeder 42 (referred to as an “empty feeder 42”) in which the reel 44 is not set and which is removed from the circuit component mounting machine 10 and corresponds to the feeder replacement work. This is an operation (reel setting operation) of setting a reel 44 containing a sufficient amount of circuit components. Another operation corresponds to the above-mentioned splicing operation, and is an operation mainly for preparing a new reel 44 (reel preparation operation). These operations will be described in detail with reference to FIG. 1. A general one of the reels 44 is housed side by side on a component shelf 150 existing between the lines. A process of searching for the necessary reel 44 from the parts shelf 150 and taking it out, and bringing the reel 44 to the preparation work area 152, or setting the further brought in the empty feeder 42 in the preparation work area 152; Become. Some of the circuit components are not stored in the component shelf 150 but are stored in a special component storage location. In the replenishment preparation work for the circuit components, it is necessary to go to the special component storage location. Work accompanies.
[0099]
Another one of the three partial operations in the operation related to parts supply is a storage location 154 (see FIG. 1) in which general circuit components (meaning other than those stored in the special component storage location) are stored. This is an operation of distributing the circuit components from to the component shelf 150 where the circuit component mounting machine 10 is located. This operation is called "parts distribution operation". In a factory where the present circuit component mounting system operates, it is assumed that some other circuit component mounting systems are operating, and in this storage location 154, general circuit components necessary for the entire factory are stored. It is assumed that The component distribution work needs to be completed before the supply preparation work in each circuit component mounting system is started. Note that the component supply operation is also a preparation operation for performing the main supply operation, and when the supply operation is interpreted in a broad sense, the component supply operation is one form of the supply operation.
[0100]
The component supply operation in the circuit component mounting system is performed by three operators 160 at a place where the circuit component mounting machine 10 is installed (see FIG. 1). The operators A and B, two of the three operators 160, are mainly engaged in the replenishment main work, and the operator C, the remaining one operator 160, is mainly engaged in the replenishment preparation work. Engage. The three operators 160 cooperate to perform a replenishment operation at the place where the circuit component mounting machine 10 is installed. In addition, the replenishment work includes, in addition to the replenishment main work and the replenishment preparation work, a work of transporting the feeder 42 or the reel 44 prepared in the preparation work area 152 so that the feeder 42 or the reel 44 is brought into a standby position before the circuit component mounting machine 10, There is an accompanying operation such as an operation of transporting the empty feeder 42 to the preparation operation area 152 and an operation of transporting the reel 44 (hereinafter, referred to as an “empty reel 44”) having no taping to a predetermined place. The accompanying work is performed by any one of the three operators 160 after judging each other's time allowance. Also, several operators 160 are arranged in the storage location 160 (FIG. 1 shows only one operator D as the person in charge of the system). Each of the operators 160 is engaged in the above-described component distribution work from the storage location 154 to the assigned circuit component mounting system.
[0101]
<Supply management of circuit parts>
In the present embodiment, component supply management relating to the circuit component mounting system is performed. The parts supply management is performed by the parts supply management system. In the present embodiment, the mounting system control device 16 also serves as a core part of the parts supply management system. As described above, the mounting system control device 16 mainly includes a computer having a general configuration including a PU (processing unit), storage means such as a ROM and a RAM, an interface, and the like. The component supply management system operates by executing a component supply management program (most of which is stored in the mounting system controller 16). FIG. 7 shows a functional block diagram of the parts supply management system. The following description will be given with reference to FIG.
(A) Management of remaining number of circuit components
First, as a premise of component supply management, management of the remaining number of circuit components performed in the component supply management system will be described. Each of the feeders 42 has an ID (feeder ID), and a bar code as an ID indicator is attached to the feeder 42. Each of the reels 44 also has an ID (reel ID), and the reel 44 is similarly provided with a bar code as an ID indicator. All the circuit components received in the factory are managed by a computer-based component management device 170 (see FIG. 1). The component management device 170 associates, for each of the reels 44, the reel ID, the component name of the circuit component contained in the reel 44, and the quantity of the circuit component contained in the reel 44 at the time of reception. It has been memorized.
[0102]
The component replenishment management system includes a component remaining number management unit 180, which manages the remaining number of circuit components supplied in the circuit component mounting system 10. The parts supply management system includes a database unit 182 having various data files, and the database unit 182 has a parts master file 184 which is one of the data files. Table 1 below shows the contents of data stored in the component master file 184.
[0103]
[Table 1]

[0104]
The component master file 184 holds the component name, the reel ID of the reel 44 containing the circuit component, and the reel 44 for each of the circuit components currently supplied in the circuit component mounting system. The feeder ID of the feeder 42 that is performing the setting, the mounting machine name of the circuit component mounting machine 10 in which the feeder 42 is provided, and the slot number that is the feeder placement position. Are stored in association with each other. The component remaining number, which is the remaining number of circuit components at the present time, is also stored in the component master file 184 as one of the storage items.
[0105]
The same applies to other tables described later, but the rotary head type circuit component mounting machines 10a and 10b in this circuit component mounting system are abbreviated as RH1 and RH2, respectively, and the XY robot type circuit component mounting machines 10c and 10d. Are abbreviated as XY1 and XY2, respectively. Slot No. In the case of the circuit component mounting machines 10a and 10b, the part before the hyphen is indicated by the number of the device table 46, and in the case of the circuit component mounting machines 10c and 10d, the part before the hyphen is separated. The number of the mounting module 94 is indicated. In order to simplify the explanation, the mode relating to the use of the device table 46 of the rotary head type circuit component mounting machines 10a and 10b employs the two-table connection mode described above in the circuit component mounting machine 10a. The machine 10b employs the two-table replacement mode described above. The table number 2 of the two device tables 46 of the circuit component mounting machine 10b is used as a spare table, and the management of the number of remaining components for the circuit components supplied from the feeder 42 disposed in the device table 46 is performed. Shall not be performed.
[0106]
As the mounting operation progresses, a supply update process for the remaining number of components is performed. The placement machine control device 14 of each circuit component placement machine 10 has a supply number counting unit that counts the number of supply components of each circuit component supplied to one circuit board. Every time slot No. is completed. And its slot No. And the number of components supplied from the feeder 42 disposed in the slot No. is reported to the mounting system controller 16. The remaining copy number management unit 180 updates the remaining number of components in the component master file 184 based on the report. By the supply update processing of the remaining parts number management unit 180, the present parts supply management system always keeps track of the remaining number of supplied circuit parts.
[0107]
In the case of a parts supply operation, a supply update process is performed in detail at the time of a main supply operation. Each of the circuit component mounting machines 10 includes a barcode reader 190 as an indicator reading device connected to the mounting machine control device 14, and uses the barcode reader 190 and the operation panel 192 of the mounting machine control device 14. Then, data for the supply update process is obtained (see FIGS. 2 and 4). The method of acquiring data differs between the case of the above-described feeder exchange operation and the case of the splicing operation.
[0108]
In the feeder replacement work, the operator 160 (the above-described operators A and B) first issues a signal to supply parts, gives an instruction to perform the feeder replacement work, and sends a slot No. in which the feeder 42 is replaced. Is input from the operation panel 192. Next, the feeder 42 in which the component has run out is removed, and thereafter, the barcode of the feeder 42 and the barcode of the reel 44 which are newly provided are read by the barcode reader 190. Next, the new feeder 42 is attached to the same slot. Then, the completion of the replacement work is input from the operation panel. With these data acquisition operations, the placement machine control device 14 causes the slot number of the replenished circuit component to be changed. , A feeder ID and a reel ID, and sends the obtained data to the mounting system controller 16. The mounting system control device 16 that has received the acquired data uses the reel ID as a key from the component management device 170 and displays the component name of the circuit component contained in the reel 44, which is associated with the reel ID. , The number of accommodated circuit components. The part remaining number management unit 180 stores the slot number. , The feeder 42 and the component name are checked, and the slot No. is checked. With the key as a key, the remaining number of circuit components for which the component master file 184 has been supplied is rewritten to the number of components stored in the new reel 44. Note that a part of the feeder ID indicates the model of the feeder 42, and in the feeder check, it is determined whether the model of the feeder 42 is the same before and after replacement.
[0109]
In the splicing operation, the operator 160 first gives an instruction to perform splicing and a signal indicating slot supply in which the feeder 42 for splicing is provided as a signal to supply parts. Is input from the operation panel 192. Next, the barcode of the reel 44 to be newly set is read by the barcode reader 190. After performing the splicing operation, information indicating completion of the operation is input from the operation panel 192. With these data acquisition operations, the placement machine control device 14 causes the slot number of the replenished circuit component to be changed. , And the acquired data is sent to the mounting system controller 16. The mounting system control device 16 that has received the acquired data uses the reel ID as a key from the component management device 170 and displays the component name of the circuit component contained in the reel 44, which is associated with the reel ID. , The number of accommodated circuit components. The part remaining number management unit 180 stores the slot number. Is used as a key to check the part name, and the slot No. Is used as a key, the remaining number of circuit components whose supply has been replenished in the component master file 184 is updated. In the case of the splicing operation, the remaining number of components at the time of replenishment is not zero, and the number of components stored on a new reel 44 is added to the remaining number of components at the time of replenishment.
[0110]
When the type of the circuit board on which the mounting operation is performed is changed, the setup of the circuit component mounting machine 10 is changed, and the supplied circuit components and the configuration related thereto are changed accordingly. Specifically, a change in the arrangement position of the feeder 42, replacement of the feeder 72, and the like are performed. At this time, initial setting is newly performed, and the component master file 184 is rewritten with a new circuit board type. In the present embodiment, in order to simplify the description, the type of the circuit board provided for the mounting operation is treated as being unchanged. Therefore, description of this initial setting is omitted here.
[0111]
(B) Execution of the parts supply management program
FIG. 8 shows a flowchart of the parts supply management program executed in the present embodiment. In the present embodiment, the replenishment schedule created by performing the parts replenishment management includes a main work schedule used for the aforementioned replenishment main work, a preparation work schedule used for the replenishment preparation work, and a replenishment work schedule used for the parts distribution work. Distribution work schedules. The execution of the parts management program is performed every elapse of a predetermined time. In the present embodiment, it is executed every minute. However, the program is set so that the preparation work schedule is executed every 5 minutes and the distribution work schedule is executed every 10 minutes. Hereinafter, the respective steps of the parts supply management will be sequentially described according to the flowchart shown in FIG.
[0112]
(C) Component outage time prediction process
First, in step 1 (hereinafter, abbreviated as "S1"; the same applies to other steps), a component outage time of each circuit component is predicted. When the mounting operation is performed according to the mounting program, the number of circuit components to be mounted on one circuit board (hereinafter referred to as “number of components to be mounted”) is determined. Specifically, which slot No. of which circuit component mounting machine 10 is used. The number of circuit components supplied from the feeder 42 disposed in the slot is used in a supply quantity file 194 (data content is omitted) of the database unit 182 to store how many circuit components are used per one circuit board. It is. Also, the mounting work time for each circuit board of the circuit component mounting machine 10 is determined, and this mounting work time is also set and stored in the database unit 182. In the present embodiment, the line tact of each line (how many seconds an electronic circuit is produced in the line) is equal to the mounting work time of each of the circuit component mounting machines 10 arranged in the line. Have been.
[0113]
As described above, the component master file 184 stores the remaining number of circuit components at the current time. In this step, the stored remaining number of circuit components and the supply quantity file 194 are stored. From the stored number of components to be mounted and the mounting operation time per circuit board, the time at which each circuit component will be cut out is predicted. Table 2 below shows the predicted component exhaustion time for each circuit component.
[0114]
[Table 2]

[0115]
Table 2 above shows that No. is assigned to each circuit component that causes a component break. (Hereinafter, referred to as “part exhaustion number”), and are arranged in the order of earliest component exhaustion time. Further, in the present embodiment, the time at which the parts are cut out is displayed in units of one minute for circuit parts whose parts are cut out after 10:00. Seconds are truncated. In other words, for example, a circuit component that is displayed as 10:02 is a circuit component that runs out of component after 10: 02: 0 before 10: 03: 0. As described above, the component outage time of each circuit component is predicted every minute. The part replenishment management system has a part exhaustion time prediction unit 196 (see FIG. 7) as a part for executing S1.
[0116]
(D) Main work schedule creation process
After the part shortage time is predicted, the main work schedule creation routine of S2 is subsequently executed to create a main work schedule used for the supply main work. FIG. 9 shows a flowchart of the main work schedule creation routine. Hereinafter, creation of the main work schedule will be described in order according to this flowchart. The main work schedule is created by the main work schedule creation unit 200 included in the supply schedule creation unit 198. The configuration of the supply schedule creation unit 198 is shown in the functional block diagram shown in FIG.
[0117]
i) Supply mode setting process
First, in S11, a supply mode of each circuit component in which a component run-out occurs is set. In the present embodiment, the replenishment mode relating to the replenishment main operation is roughly classified into three types. One of them is a replenishment mode in which components are replenished immediately upon occurrence of a component shortage (hereinafter referred to as “component replenishment mode”). In the replenishment mode at the time of component exhaustion, specifically, when the component exhaustion occurs and the circuit component mounting machine 10 stops, the above-described feeder replacement operation is immediately performed. One of the replenishment modes is a replenishment mode in which a main replenishment operation is performed until a set time elapses after the occurrence of a component shortage (hereinafter, referred to as a “supply mode after a component shortage”). The replenishment mode after component exhaustion is, specifically, a feeder replacement operation for the circuit component in which the next device is set and a feeder replacement operation in the circuit component mounting machines 10a and 10b in which the two-table replacement mode is set. included. Another replenishment mode is a replenishment mode in which a main replenishment operation is performed within a set time before a component shortage occurs (hereinafter, referred to as “supply mode before component depletion”). The above-mentioned splicing operation specifically corresponds to the replenishment mode before part exhaustion.
[0118]
The database unit 182 has a table mode file 202. The table mode file 202 includes, as one of the specifications relating to the mounting operation of the circuit component mounting machine 10, a device table set in each circuit component mounting machine 10. Operation modes (mounting machine table mode) 46 and 102 are stored. Table 3 below shows the stored contents.
[0119]
[Table 3]

[0120]
As can be seen from Table 3, as described above, the two-table connection mode and the two-table replacement mode are set in the rotary head type circuit component mounting machines 10a and 10b, respectively, and the XY robot type circuit component mounting is performed. In the machines 10c and 10, the one-table fixed mode is set.
[0121]
Further, the database unit 182 has a next device setting file 204. The next device setting file 204 includes, in the slot, the next device data as one of the data relating to the mounting operation, more specifically, one data relating to the supply form of the circuit components. Whether the device setting has been made or not is determined by the slot number. Is stored in association with. Table 4 below shows the stored contents.
[0122]
[Table 4]

[0123]
In the above table 4, the slot number where [ND] is displayed in the item of the next device is shown. The next device is set for the feeder 42 disposed in the slot of No. 1. As an example, from Table 4, [2-05], [2-06] and [2-07] of the circuit component mounting machine 10a and [1-08] and [1-09] of the circuit component mounting machine 10c are shown in Table 4. It can be understood that the next device is set in the feeder 42 provided in the slots [1-13], [1-14], and [1-15] of the circuit component mounting machine 10d. Since the circuit component mounting machine 10b operates in the two-table replacement mode, no next device is set in any slot.
[0124]
Further, the database unit 182 has a component specification setting file 206. In the component specification setting file 206, splicing is possible for each circuit component as one of the specifications regarding the supplied circuit component. The presence or absence is stored in association with the component name of each circuit component. Table 5 below shows splicing settings for each circuit component, which is the storage content of the file. The table shown in Table 5 also describes the setting of the component storage location, which will be described later.
[0125]
[Table 5]

[0126]
In the above Table 5, splicing is set for the circuit component whose component name is displayed as [SP] in the splicing section. As an example, it can be seen from Table 5 that the circuit components having the component names [ABJ2121], [ABJ2122], [HTY4578], and [HTY4579] can be spliced. In this embodiment, as long as the XY robot-type circuit component mounting apparatuses 10c and 10d are used, splicing work is performed on circuit components for which splicing is set.
[0127]
The setting of the supply mode of each circuit component is performed based on the data stored in the table mode file 202, the next device setting file 204, and the component specification setting file 206. Specifically, the component name, mounting machine name, slot No. Is used as a key (see Table 2), the above three files are searched, and it is determined which of the three replenishment modes each circuit component belongs to. Table 6 below shows the association between the above-mentioned specifications concerning the component supply mode, circuit components, and the like and the component supply mode, which are the storage contents of the file.
[0128]
[Table 6]

[0129]
The supply mode of each circuit component is set according to Table 6 above. “SP” in Table 6 is an abbreviation for splicing, and “ND” is an abbreviation for the next device. In the replenishment mode, [A] is a symbol indicating a replenishment mode when parts are exhausted, [B] is a replenishment mode after component exhaustion by the next device, and [B '] is a component replenishment mode. Symbols indicating the two-table replacement mode in the post-supply mode and [C] indicating the replenishment mode before component exhaustion, respectively, are used. Hereinafter, these abbreviations and symbols are appropriately used.
[0130]
Table 7 below shows the replenishment mode set for each circuit component in which the component runs out as a result of the replenishment mode setting process. As can be understood from Table 7, each circuit component that is out of components is classified into one of the replenishment modes, and the replenishment mode is set. The setting of the supply mode described above is executed by the supply mode setting unit 208.
[0131]
[Table 7]

[0132]
ii) Estimated main work time
Subsequently, in S12, a time serving as a guideline for performing a replenishment main work for each circuit component, that is, an estimated main work time, is determined based on the predicted part-out time of each circuit component. S12 includes two sub-steps S13 and S14. In S13, a main work start time which is a time at which the main supply work can be started or permitted is determined, and in S14, a main supply start time is determined. A main work end time is determined, which is the time at which the work must be completed or desired to be completed.
[0133]
The main work start time and the main work end time are determined depending on the set supply mode. The database unit 182 has a replenishment mode dependent time determination file 210. The replenishment mode dependent time determination file 210 includes a replenishment mode dependent time determination file 210 based on the replenishment mode, as shown in Table 8 below. A start time determination time and an end time determination time set for determining the main work start time and the main work end time are stored.
[0134]
[Table 8]

[0135]
The main work start time is determined by adding the start time determination time shown in Table 8 to the part exhaustion time, and the main work end time is determined by adding the end time determination time shown in Table 8 to the component exhaustion time. Is done. In the case of the part replenishment mode [A], since the feeder replacement work is performed immediately after the part runs out, the start time and the end time of the main work are substantially equal to the part out time, and the start time determination time and the end time determination are made. Both times are set to 0 minutes. In the case of the replenishment mode [B] after the component is exhausted by the next device, the feeder can be replaced after the component has been exhausted, and the exchange is allowed even after a considerable time has elapsed since the component was exhausted. The start time determination time is set to 0 minutes, and the end time determination time is set to +5 minutes. In the case of the replenishment mode [B '] after the parts run out in the two-table replacement mode, the feeder replacement work is possible from the time the parts run out, and it is desirable to replace the feeder within a relatively short time after the parts run out. The time determination time is set to 0 minutes, and the end time determination time is set to +2 minutes. In the replenishment mode before parts shortage [C], taking into account that splicing work is difficult even if it is too early or too late, the work allowable time is set between 4 minutes and 2 minutes when parts run out. The start time determination time is set to -4 minutes, and the end time determination time is set to -2 minutes.
[0136]
In Table 9 below, the main work start time and the main work end time of each circuit component obtained by adding the start time determination time and the end time determination time are shown in a table format together with the part outage time.
[0137]
[Table 9]

[0138]
In Table 9 above, ΔT1 is the start time determination time, ΔT2 is the end time determination time, T0 is the component out time, T1 is the main work startable time, and T2 is the main work required end time. (The same may be omitted hereinafter). If there is a time difference between the main work start time and the main work end time, the main work start time means that the work can be started at that time, for example, at 10:00 to simplify the description. In this case, it means that it is possible to start the work from 10:00 to 10: 1. In this case, the main work end time means to end before the time comes. For example, if the time is 10:02, it means to end at 10:01. The standard times for the main work are determined by the above-described processing. The standard times are determined by the main work standard time determination unit 212 in the main work schedule creation unit 200. A certain main work start time is determined by the estimated start time determination unit 214, and a main work end time, which is an estimated end time of the work, is determined by the estimated end time determination unit 216. In addition, since the main work reference time determination unit 212 determines the reference time based on the supply form, it can be said that the main work reference time determination unit 212 includes the supply form dependence determination unit 218.
[0139]
iii) Time chart of main work schedule
Here, the main work schedule based on the estimated main work time is shown in Table 10 below as a time chart.
[0140]
[Table 10]

[0141]
In the time chart, [●] and [○] indicate the time at which the parts have run out, but [●] means that the replenishment main work can be performed in the time zone to which the time at which the parts run out, and [○] means This means that the replenishment main work is not permitted in the time zone to which the part exhaustion time belongs. In the chart shown in Table 10 above, [●] indicates the part-out time of the circuit component set to be in the replenishment mode at the time of component outage or after the component depletion, and [○] indicates the replenishment mode before the component exhaustion. Is the component outage time of the circuit component set as follows. [-] Indicates that the time zone is a time zone in which a feeder replacement operation is to be performed after the component runs out, and [=] indicates that the time zone is a time zone in which a splicing operation is possible. Through the above-described processing, a schedule as shown in Table 10, that is, one schedule relating to the main supply work based on the estimated main work time is created, and S12 ends.
[0142]
iv) Main work schedule adjustment process
In the next S15, schedule adjustment is performed on the main work schedule created based on the estimated main work time as described above. This schedule adjustment is performed by the main work schedule adjustment unit 230. The schedule adjusting step of S15 includes several sub-steps. First, in S16 which is one of the sub-steps, it is determined whether or not there is an overcrowded time zone which is a time zone in which the main work schedule becomes overcrowded. Is determined.
[0143]
The database unit 182 has a main work required time file 232. The main work required time file 232 includes a standard required time for a supply main work for one circuit component as shown in Table 11 below. Is stored. The main work required time is set for each of the replenishment modes.
[0144]
[Table 11]

[0145]
As can be seen from Table 11, in the present embodiment, specifically, the replenishment mode before running out of parts for performing a splicing operation that requires a relatively long working time is set to 1 minute, and when the parts run out for performing the feeder replacement operation and after the parts run out. The supply mode is set to 0.5 minutes. The number of operators 160 engaged in the main supply operation is also set and stored in the database unit 182. The time period used as a reference for determining the overcrowded time period has a time width of 1 minute, and the total required time of the main replenishment operation in a certain time period is calculated by multiplying the above time width by the number of operators 160 engaged in the main supply operation. If the workable time within the time zone is exceeded, the time zone is recognized as an overcrowded time zone. In the case of the present embodiment, there are two operators 160 engaged in the replenishment main work, and the workable time within the time zone is 2 minutes. That is, in S16, the overcrowded state is determined based on the required work time in the replenishment main work and the number of operators.
[0146]
Table 12 below shows the total required time (represented as “before adjustment”) of the main supply operation in each time zone. Table 12 also shows the total required time after the schedule adjustment, which will be described later.
[0147]
[Table 12]

[0148]
For simplicity, the total required time in each time slot is shown in Table 10 when [●] [-] [=] belongs to a certain time slot in the main work schedule shown in the chart of Table 10. And the total required time. Specifically, a value obtained by the formula of [number of [●] × 0.5 + number of [−] × 0.5 + [=] × 1] is set as the total required time of the time zone. As can be seen from Table 12, in the present embodiment, the time zones [10:10], [10:11], and [10:21] indicated by * are overcrowded. The process of identifying the overcrowded time zone in S16 is executed by the overcrowded time zone identifying unit 234 of the main work schedule adjusting unit 230.
[0149]
Next, in S17, if the overcrowded time zone exists, the estimated main work time is changed in order to alleviate the overcrowded state in the time zone. In principle, the change process is performed so that the overcrowded state is avoided, that is, the total required time in the overcrowded time zone is within the workable time within the above-mentioned time slot. At this time, the main work start possible time or the main work required end time is changed on condition that the replenishment main work can be performed as early as possible. When the main work start possible time is changed to a later time zone, priority is given to those having a long work possible time (specifically, circuit components in replenishment mode B).
[0150]
This will be specifically described below with reference to the chart shown in Table 10. In the time zone [10:10], the part no. The main work end time for the circuit component is changed so that the replenishment main work (A in Table 10) for the circuit component of [5] is prohibited. Further, in that time zone, the part no. The main work start time for the circuit component is changed so as to prohibit the replenishment main work (B in Table 10) for the circuit component of [6]. In the time zone [10:11], the part no. The main work end time for the circuit component is changed so as to prohibit the replenishment main work (C in Table 10) for the circuit component of [10]. Also, in the time zone [10:21], the part exhaustion No. The main work start time for the circuit component is changed so as to prohibit the replenishment main work (D in Table 10) for the circuit component of [17]. The change of the estimated main work time in S17 is executed by the estimated time change unit 236.
[0151]
In Table 13 below, the main work start time and the main work end time before and after the adjustment are shown together with the parts out time.
[0152]
[Table 13]

[0153]
In Table 13 above, T1 'is the adjusted main work start time, and T2' is the adjusted main work end time. The time marked with * is the time that was changed. By this schedule adjustment, as shown in Table 12, the total required time in the time zones [10:10], [10:11], and [10:21] changes. The total required time is within the workable time within the time zone, and the overcrowded state is eliminated. The schedule is adjusted as described above, and the main work schedule creation routine in S2 ends. Note that the main work schedule adjustment unit 230 including the overcrowded time zone recognition unit 234 and the estimated main work time change unit 236 includes the overcrowding correspondence adjustment unit 238 that adjusts the schedule according to the overcrowding state. is there.
[0154]
(E) Main work schedule display process
Following S2, in S3, the created main work schedule is displayed. A main work schedule display device 250 (see FIGS. 1 and 7) mainly composed of a computer for displaying the main work schedule is arranged between the two lines. The information is output to the monitor of the display device 250, and is displayed to the operator 160. The mounting system control device 16 is provided with a schedule data transmission unit 252 (see FIG. 7) as a functional part of the parts supply management system. The main work schedule data including the information on the parts used for the parts, such as the estimated main work time and the part name, is transmitted. The main work schedule display device 250 receives the data, creates a display screen in a predetermined format based on the data, and displays it on the monitor. In the parts supply management system, the main work schedule display device 250 functions as a schedule display unit (an example of a schedule notification unit).
[0155]
Table 14 below shows the main work schedule displayed on the main work schedule display device 250. The main work schedule is generally displayed in a format as shown in Table 14.
[0156]
[Table 14]

[0157]
As can be understood from Table 14, the displayed contents include a time chart in which the predicted component exhaustion time and the estimated main work time of the circuit component whose component exhaustion is predicted are symbolized and arranged in chronological order. No-part No. of circuit parts , The name of the component, the name of the mounting machine in which the feeder 42 for supplying each circuit component is provided, and the slot number. , Next device setting, splicing setting, etc. As can be understood from comparison with Table 10, in the display contents shown in Table 14, the locations of A, B, C, and D in Table 10 have been changed to alleviate the overcrowded state. The operator 160 engaged in the main supply operation performs the main supply operation using the displayed main operation schedule as a guideline. Since the schedule is created in detail, efficient parts supply can be performed.
[0158]
After S3 ends, in S4, it is determined whether or not to create a preparation work schedule. As described above, the preparation work schedule is performed every five minutes, and if five minutes have elapsed since the last preparation work schedule creation, the preparation work schedule creation routine of S5 is executed. If five minutes have not elapsed, the execution of the parts supply management program is stopped until the next start (about one minute later).
[0159]
(F) Preparation work schedule creation process
If it is determined in S4 that a preparation work schedule is to be created, a preparation work schedule creation routine is executed in S5. FIG. 11 shows a flowchart of the preparation work schedule creation routine. Hereinafter, the processing of this routine will be described with reference to this flowchart. The preparation work schedule is created by the preparation work schedule creation unit 260 included in the supply schedule creation unit 198.
i) Preparatory work required time setting process
First, in S21, a preparation work required time is set for each circuit component in which the component runs out. As described above, the component specification setting file 206 included in the database unit 182 includes information on whether each circuit component is a component to be spliced, whether the circuit component is in a special storage location (a general storage location 154). (Other locations). The database unit 182 has a preparatory work required time file 262. As shown in Table 15, the preparatory work required time file 262 stores standard replenishment preparation work for one circuit component. The required time for the preparation work, which is the required time, is set and stored. The time required for the preparation work is set in association with whether the work is a splicing work and whether the work is stored in a special storage place.
[0160]
[Table 15]

[0161]
As can be seen from Table 15, in the case of the circuit components stored in the special storage location, it is considered that the operator 160 (the operator C described above) performing the preparatory work has to go to the location by himself to pick up the circuit components. Then, the required time is set longer by that much. Also, when the main replenishment operation is a feeder replacement operation, the above-described reel setting operation must be performed in the replenishment preparation operation. Therefore, a circuit component that does not perform splicing requires a longer time than a circuit component that performs splicing. It is set long. Based on the specifications of each circuit component and the set standard preparation operation required time, the required time for the replenishment preparation operation for each circuit component that causes a component shortage is set. The setting of the required preparatory work time in S21 is executed by the preparatory work required time setting unit 264. Table 16 below shows the required preparatory work time for each set circuit component.
[0162]
[Table 16]

[0163]
ii) Estimated preparation work time
Subsequently, in S22, a preparation work reference time serving as a reference of the replenishment preparation work is determined. S22 includes several sub-steps. Each time each sub-step is executed, the estimated time of the preparation work according to the execution stage is determined, and when S22 is completed, it becomes a reference for creating a schedule. Estimated time is determined. Table 17 below shows the approximate preparation work times in the order in which they are determined. Hereinafter, description will be made with reference to Table 17.
[0164]
[Table 17]

[0165]
First, in S23, a limit time, which is a reference time serving as a reference for a reference time for preparation work described later, is determined. The limit time is a time at which the preparatory work must be completed by that time, and in that sense, it can be said to be one type of work end guide time. The limit time is determined to be the earlier of the main work start time before the adjustment and the main work start time after the adjustment among the reference times of the main work.
[0166]
Next, in S24, the margin addition time is determined by adding the margin time to the above-mentioned margin time and moving up the margin time. The spare time is a time set in consideration of an unexpected situation or the like in order to smoothly perform a work related to parts replenishment, and is set uniformly for all circuit components and stored in the database unit 182. I have. In the present embodiment, it is one minute. It can be said that this extra time is also a kind of the estimated work end time.
[0167]
Next, in S25, the required time-added time is determined by advancing the margin-added time in consideration of the preparation time required for each circuit component set in S21. The required time addition time is a time at which the replenishment preparation work must be started at least by that time in order to end the supply preparation work by the margin addition time. In that sense, it can be said that the required time-added time is one type of the estimated work start time. Since the required time for the preparation work has a fraction of less than one minute, the time including the required time may be a fraction, but in that case, the time is further advanced.
[0168]
In the following S26, an estimated preparation work time zone for each circuit component is determined. In the present embodiment, a reference time zone of 5 minutes is set such as xx: 00 to xx: 05, xx: 05 to xx: 10, xx10 to xx: 15,. The time zone to which the added time belongs is determined as a reference time zone for preparing the circuit component. The guideline for the preparation work can be considered as a rough reference time, and in the present embodiment, this time slot is also treated as one reference time for the preparation work. Note that S23, S24, S26, and S27 are respectively performed by the limit time determination unit 266, the spare time dependence determination unit 268, the required work time dependence determination unit 270, and the reference time zone determination unit 272 included in the preparation work reference time determination unit 268. Be executed. The preparation work reference time determination unit 274 includes these components.
[0169]
iii) Prepared work schedule
Table 18 below shows the preparation work schedule created based on the preparation work reference time determined in S22, specifically, the preparation work reference time zone. In Table 18, for each time zone, which circuit component is to be subjected to the replenishment preparation work is shown together with the required work time for that circuit component. In Table 18, data on circuit components predicted to be out of component after 10:26 is added.
[0170]
[Table 18]

[0171]
iv) Preparation work schedule adjustment process
The preparation work schedule created after S22 is adjusted in S27. The schedule adjustment is performed by the preparation work schedule adjustment unit 280. S27 includes several sub-steps. First, in S28, it is determined whether or not there is an overcrowded time zone in the preparation work schedule. The determination is made based on whether or not the total required time, which is the sum of the required work times of the circuit components belonging to one time zone, exceeds the available work time within the time zone. If the time is exceeded, the time zone is recognized as an overcrowded time zone. The number of operators 160 engaged in the replenishment preparation work is set and stored in the database unit 182, and the workable time within the time zone is set based on the number of workers. In the present embodiment, one operator 160 is engaged, and the workable time within the time zone is set to 5 minutes. Table 19 below shows the total preparation work required time for each time zone. Note that the total required time after the adjustment is also shown, which will be described later.
[0172]
[Table 19]

[0173]
According to Table 19, in the reference time periods [10:05 to 10:10] and [10:15 to 10:20] marked with *, the total required time is the workable time within the time period. It was over 5 minutes, indicating that it was overcrowded. These time zones are recognized as overcrowded time zones.
[0174]
Next, when an overcrowded time zone exists, in S29, a schedule adjustment is performed to alleviate the overcrowded state in the time zone. Specifically, adjustment is performed so that the replenishment preparation work for any of the circuit components belonging to the overcrowded time zone is brought forward in a time zone before the time zone. That is, the preparation work reference time zone, which is the reference time, is changed. In this case, the replenishment preparation work is shifted preferentially to the one with the earlier required time taking into account the required time, and until the total required time in the time zone becomes smaller than the workable time in the time zone. More specifically, with reference to Table 18, the part out of No. belonging to the time zone [10:05 to 10:10]. [5], the replenishment preparation work for the part name [JBG7411] is shifted to [10:00 to 10:05], and a part out of No. belonging to [10:15 to 10:20]. [13], the replenishment preparation work for the part name [JDS9614] is shifted to [10:10 to 10:15]. If the preceding time zone becomes overcrowded as a result of being brought forward, readjustment is performed for that time zone. In principle, adjustments will be made to eliminate overcrowding at all times.
[0175]
After the adjustment corresponding to the overcrowded state, in S30, the adjustment corresponding to the work prohibition time is performed. A rest time is set in the replenishment preparation work, and the rest time is set as a work inhibition time. In the case of the present embodiment, [10:20 to 10:25] is set as a break time, and the set work prohibition time is stored in the database unit 182 (the time indicated by ◎ in Table 19). band). The adjustment corresponding to the work prohibition time zone is performed so that all the work on the circuit components belonging to the time zone is brought forward in the previous time zone. This will be described in detail with reference to Table 18. [21], the part name [EES3535] and the part no. [23], the replenishment preparation work for the part name [FDD4420] is shifted to [10:20 to 10:25]. If the preceding time zone becomes overcrowded as a result of being brought forward, readjustment is performed for that time zone in accordance with the previous processing procedure. Even in such a case, adjustment is made so that overcrowding in all time zones is eliminated in principle.
[0176]
After the above-described schedule adjustment is performed, S27 ends, and the preparation work schedule creation routine of S5 ends. Adjustment The schedule adjustment in the above two aspects is performed by the overcrowding adjustment unit 282 and the prohibited time adjustment unit 284 included in the preparation work schedule adjustment unit 280. S28 and S29 are executed by the overcrowding adjustment unit 282, and S30 is executed by the prohibition time adjustment unit 284. The adjusted preparation work schedule as a result of the schedule adjustment is shown in Table 20 below. Table 19 shows the total required time in each time zone after the adjustment.
[0177]
[Table 20]

[0178]
(G) Preparation work schedule display process
Following S5, in S6, the prepared preparation work schedule is displayed. In the vicinity of the preparation work area 152, a preparation work schedule display device 290 (see FIGS. 1 and 7) mainly composed of a computer for displaying the preparation work schedule is arranged. The data is output to the monitor of the schedule display device 290, and is displayed to the operator 160. The above-mentioned schedule data transmitting unit 252 transmits the preparation work schedule data including the part-out part information such as the preparation work reference time zone and the part name for each circuit component predicted to be out of parts. The preparation work schedule display device 290 receives the data, creates a display screen in a predetermined format based on the data, and displays the display screen on the monitor. The preparation work schedule display device 290 also functions as a schedule display unit.
[0179]
Table 21 below shows the preparation work schedule displayed on the preparation work schedule display device 290. The preparation work schedule is generally displayed in a table format as shown in Table 21.
[0180]
[Table 21]

[0181]
As can be seen from Table 21 above, the displayed contents are the name of the component, the name of the mounting machine in which it is disposed, the splicing setting, the storage location, and the above-mentioned required time taking into account the time of the circuit component whose component is expected to run out. This is the part information about the missing parts. These pieces of part information are classified and displayed according to the preparatory work reference time zone and therefore according to the time zone. In each time zone, the circuit components are displayed in ascending order of required time. The operator 160 engaged in the replenishment preparation work performs the replenishment preparation work using the displayed preparation work schedule as a guideline. Specifically, in principle, the replenishment preparation work for each circuit component belonging to one time zone is performed in time for each required time. The preparation work schedule display device 290 has an information input device, and can input information indicating that the replenishment preparation work has been completed. Based on this information, the preparation work schedule is displayed. Items related to completed circuit components are deleted. The information is sent to the mounting system control device 16, and based on the information, the circuit component for which the replenishment preparation work has been completed is excluded from the schedule creation target when the next preparation work schedule is created.
[0182]
After S6 ends, it is determined in S7 whether or not to create a distribution work schedule. As described above, the distribution work schedule is performed when 10 minutes have elapsed, and if 10 minutes have elapsed since the last distribution work schedule creation, the preparation work schedule creation routine of S8 is executed. If 10 minutes have not elapsed, the execution of the parts supply management program is stopped until the next start (after about 1 minute).
[0183]
(H) Distribution work schedule creation process
If it is determined in S7 that a distribution work schedule is to be created, a distribution work schedule creation routine is executed in S8. FIG. 12 shows a flowchart of the distribution work schedule creation routine. Hereinafter, the processing of this routine will be described with reference to this flowchart. The creation of the distribution work schedule is performed by the distribution work schedule creation unit 292 of the supply schedule creation unit 198.
[0184]
i) Distribution work guide time determination process
First, in S41, a reference distribution work time serving as a reference of the component distribution work is determined. Specifically, the time that is the starting point of the estimated preparation work time zone determined in the preparation of the preparation work schedule is determined as the estimated distribution work time of each circuit component. This time is a time at which it is assumed that the circuit components expected to run out of components must be transported from the storage location 154 to the component shelves 150 arranged on the line, and serve as a guideline for ending the component distribution work. It is time. In other words, this time plays a role as a work end guide time for the parts distribution work. This S41 is executed by the distribution work reference time determination unit 294. The estimated distribution work estimated times are shown in Table 22 below in a table format.
[0185]
[Table 22]

[0186]
ii) Special storage location parts deletion process
Subsequently, in S42, the parts stored in the special storage location are excluded from the distribution work schedule. This is because the distribution work schedule targets only the circuit components stored in the general component storage location 154. This S42 is executed by the non-target component excluding unit 296. The non-target parts are deleted to create a distribution schedule, and the distribution schedule creation routine in S8 ends. Table 23 below shows the created distribution schedule.
[0187]
[Table 23]

[0188]
(I) Distribution work schedule display process
Following S8, in S9, the created distribution work schedule is displayed. A distribution work schedule display device 298 (see FIGS. 1 and 7) mainly composed of a computer for displaying a distribution work schedule is arranged in a storage place 154 where general circuit components are stored. Is output to the monitor of the distribution work schedule display device 298, and is displayed to the operator 160 (the operator D described above) engaged in the parts distribution work. The above-described schedule data transmission unit 252 transmits distribution work schedule data including part-out part information such as the part name of each circuit part. The distribution work schedule display device 298 receives the data, creates a display screen of a predetermined format based on the data, and displays the display screen on the monitor. The distribution work schedule display device 298 also functions as a schedule display unit. The display format of the distribution work schedule is the same as the format shown in Table 23 above, and therefore, the description here is omitted.
[0189]
The operator 160 engaged in the parts distribution work performs the parts distribution work using the displayed distribution schedule as a guideline. Note that the distribution work schedule display device 298 also has an information input device, and can input information indicating that the part distribution work has been completed. Based on this information, the displayed distribution work schedule is displayed. Circuit components that have been distributed are deleted. Further, the information is sent to the mounting system control device 16, and based on the information, the circuit component for which the distribution work has been completed is excluded from the schedule creation target when the next distribution work schedule is created. After the completion of S9, the execution of the parts supply management program is stopped until the next start (after about one minute).
[Brief description of the drawings]
FIG. 1 is a schematic diagram showing an overall configuration of a circuit component mounting system to which the present invention is applied.
FIG. 2 is a perspective view of the rotary head type circuit component mounting machine as viewed from the front side thereof.
FIG. 3 is a perspective view of the rotary head type circuit component mounting machine as viewed from the rear side thereof.
FIG. 4 is a perspective view of the XY robot-type circuit component mounting machine viewed from the front side thereof.
FIG. 5 is a perspective view showing an internal structure of a mounting module constituting the XY robot type circuit component mounting machine.
FIG. 6 is a perspective view showing a mounting device included in the mounting module.
FIG. 7 is a functional block diagram illustrating a configuration of a parts supply management system according to an embodiment of the present invention.
FIG. 8 is a flowchart of a parts supply management program according to an embodiment of the present invention.
FIG. 9 is a flowchart of a main work schedule creation routine.
FIG. 10 is a functional block diagram illustrating a configuration of a supply schedule creation unit.
FIG. 11 is a flowchart of a preparation work schedule creation routine.
FIG. 12 is a flowchart of a distribution work schedule creation routine.
[Explanation of symbols]
10: Circuit component mounting machine (10a, 10b: rotary head type, 10c, 10d: XY robot type) 14: Mounting device control device 16: Mounting system control device
40: Component supply device 42: Tape feeder (component supply device) 44: Reel 46: Device table 100: Component supply device 102: Device table 150: Component shelf 154: Storage location 170: Component management device 180: Component remaining number management unit 182: Database section 196: Component outage time prediction section 198: Supply schedule creation section 200: Main work schedule creation section 208: Supply form setting section 212: Main work guide time determination section 214: Start guide time determination section 216: End guide time Determination unit 218: Supply form dependence determination unit 230: Main work schedule adjustment unit 238: Overcrowding correspondence adjustment unit 250: Main work schedule display unit 260: Preparation work schedule creation unit 264: Preparation work required time determination unit
268: spare time dependence determination unit 270: work required time dependence determination unit 272: guide time zone determination unit 274: preparation work reference time determination unit 280: preparation work schedule adjustment unit 282: overcrowding correspondence adjustment unit 284: prohibited time correspondence adjustment unit 290: preparation work schedule display device 292: distribution schedule creation unit 294: distribution work reference time determination unit 298: distribution work schedule display device

Claims (10)

A circuit supplied and used in a circuit component mounting system including a plurality of circuit component mounting machines for disposing a plurality of component supply devices for supplying circuit components and mounting circuit components supplied from the component supply device on a circuit board. A parts supply management system for managing parts supply timing,
A component out time predicting unit that predicts the component out time of each of the circuit components from the remaining number of each circuit component,
A replenishment schedule creating unit that creates a replenishment schedule that can be used for work related to component replenishment based on the component out time of each of the circuit components,
A parts replenishment management system including a replenishment schedule notifying unit that notifies the operator of the replenishment schedule. The replenishment schedule creating unit includes a reference time determination unit that determines a reference work time of each circuit component, which is a reference for performing a work related to the component supply, based on a component out time of each of the circuit components. 2. The parts supply management system according to claim 1, wherein the supply schedule is created based on the estimated work time. The component supply management system according to claim 2, wherein the reference time determination unit includes a supply mode dependence determination unit that determines an operation reference time of each circuit component based on a supply mode of each circuit component. 4. The work required time determination unit according to claim 2 or 3, wherein the reference time determination unit includes a required work time determination unit that determines a reference work time of each circuit component based on a required work time of each circuit component in the work related to the component replenishment. Described parts supply management system. 3. The schedule adjusting unit according to claim 1, wherein the replenishment schedule creating unit includes a schedule adjusting unit that, when it is determined that the replenishment schedule to be created requires adjustment, adjusts the replenishment schedule according to a predetermined adjustment condition. 4. The parts supply management system according to any one of 4. When it is determined that there is an overcrowded time zone in which the work related to the component supply according to the created replenishment schedule is overcrowded, the schedule adjustment unit performs a schedule adjustment to reduce the overcrowded state. The parts supply management system according to claim 5, comprising: 7. The parts supply management system according to claim 1, wherein the parts supply management system includes a plurality of the supply schedule creation units, and the plurality of supply schedule creation units create each of a plurality of supply schedules having different usage purposes. The parts supply management system according to any of the above. Each of the plurality of replenishment schedule creation units creates the replenishment schedule in which operations related to the target component replenishment are different from each other,
The plurality of replenishment schedule creation units, a main work schedule creation unit that creates a main work schedule that can be used for a replenishment main work that replenishes the circuit component mounting machine with replenishment parts, and until the circuit component mounting machine can be replenished. 8. The parts supply management system according to claim 7, further comprising at least one of a preparation work schedule creation unit that creates a preparation work schedule that can be used for a supply preparation work for preparing supply parts. A circuit provided with a plurality of component supply devices for supplying circuit components and provided for a circuit component mounting system including at least one circuit component mounting machine for mounting a circuit component supplied from the component supply device on a circuit board. A parts supply management method for managing a parts supply time,
A component outage time prediction step of predicting the component outage time of each circuit component from the remaining number of each circuit component,
A replenishment schedule creating step of creating a replenishment schedule that can be used for work related to component replenishment based on the component out-of-time of each circuit component,
A supply schedule notifying step of notifying an operator of the supply schedule. A circuit provided with a plurality of component supply devices for supplying circuit components and provided for a circuit component mounting system including at least one circuit component mounting machine for mounting a circuit component supplied from the component supply device on a circuit board. A parts supply management program executed by a computer to manage a parts supply time,
A component outage time prediction step of predicting a component outage time of each of the circuit components from the remaining number of each circuit component,
A replenishment schedule creating step of creating a replenishment schedule that can be used for work related to component replenishment based on the component out-of-time of each of the circuit components,
A supply schedule notifying step of notifying the operator of the supply schedule.

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