JP2562519B2 - Manufacturing control system - Google Patents

Description

TECHNICAL FIELD The present invention relates to a manufacturing control system including a manufacturing facility and a physical distribution facility, and more particularly to a control management system for a unit assembly line.

[Background technology]

In the field of electronic devices, products are becoming smaller, lighter and more multifunctional in recent years, and the printed circuit board units that make up these products are increasingly mounted at high density. Accompanying this, it has become difficult to mount components by hand due to an increase in the number of components mounted, miniaturization and complexity of components, and many automatic component insertion machines and mounting machines have been introduced in factories. . In addition, there is a demand for efficiently operating those expensive equipment introduced due to the soaring labor cost of the factory as much as possible without any personnel.
On the other hand, diversifying customer needs and shortening the life cycle of products are progressing, and in factories, it is obligatory to reduce the number of products and shorten the delivery time, which becomes a factor that obstructs the demand for unmanned and highly efficient products. ing.

Conventionally, various attempts have been made to unmanned and improve efficiency for each type of product in individual equipment arranged on the production line. No unmanned and highly efficient system has been realized.

[Disclosure of Invention]

In view of the above problems, it is an object of the present invention to realize line control / management aimed at improving the productivity of a production control system and unmanning a line, even in response to demands for a large variety of products and a short delivery period.

In order to achieve the above-mentioned object, what is provided by the present invention is to provide a plurality of equipment including a component mounter that performs a plurality of processes on a plurality of products, and a plurality of equipment for controlling these equipment. Cell controller, a line control system for centrally controlling all of the cell controllers, and a transportation means for transporting between the facilities under the control of the line control system. The line control system cuts out from a relatively long-term schedule. Create a detailed execution schedule that takes into account the relatively short-term plan, the in-process status in the product line, and the actual occurrence event in real time,
The manufacturing control system is configured to control the equipment, the cell controller, the component mounter, and the transportation means based on the created execution schedule.

The line control system analyzes the alarm from the equipment, which is one of the above-mentioned actual occurrence events detected by the cell controller, and if it is determined that the recovery is impossible or it takes time to recover, the equipment is It is preferable to automatically perform rescheduling to recreate the execution schedule, and to display a message prompting rescheduling when the cause of the failure is unknown even after analyzing the alarm.

When a predetermined time is required for the setup for changing the processing conditions between processes, the line control system calculates the total working time of the products input for each process, and the line control system calculates the total number of working hours in descending order of the total value. Group of products grouped in the sort table, and a priority table for storing the processes in order and a sort table for storing the products in order of the process conditions according to the order. Or, arrange the products so that the processing conditions for adjacent groups of products or products match as much as possible, and determine the order of loading by grouping so that the number of setup times is the smallest in the order of the total value of the working time. It is preferable to create an execution schedule.

As one of the actual events that occur, there is a demand for express goods, and when there is a demand for express goods, the express goods should be given the highest priority, or the margin for delivery of the express goods should be reduced or set to zero. It is preferable to create an execution schedule.

It is equipped with a free time management table for managing free time for each process, a processing history table for leaving a history of jobs processed in that process, and a transfer man-hour table for considering the transfer time between processes. A job has a process route and man-hours in each process, and an execution schedule is created by recursively simulating the input time, end time, and discharge time to the next process according to the process route for each job. Is preferably created.

It is preferable that the line control system includes a schedule performance comparison unit that constantly compares the execution schedule and the performance from the component mounter, and a warning generation unit that detects a difference due to the comparison and issues a warning.

It is preferable that the warning generation unit issues a warning to a worker of the unit assembly line control system in real time.

Each facility is equipped with a product detection unit that detects the presence or absence of a product at the product inlet, and the line control system manages the work schedule of each facility, the process route for each product, and the current location. When the product detection unit detects that the input port of the equipment is empty, the line control system refers to the process route management table and indicates the schedule management table. It is preferable to check in which facility the product to be carried in is currently located and instruct the carrying means to carry the product.

Each piece of equipment is equipped with a product detector that detects the presence or absence of a product at the product inlet, and when the product detector detects that there is no product at the inlets of multiple equipment, the product to be received next If there is no product in the input port of the equipment, the transfer request generation means for requesting the transfer is provided, and if there is no product in the input port, the transfer request means requests the transfer of the next product. The line control system collates the content of the transport request generated by the transport request unit with the processed product, and when there is a product with the collated result, it can issue a product transport command to the transport means. preferable.

The component mounter is equipped with an unmounted component detection unit that detects unmounted components, and when a component is out of stock during product processing, the information on the missing component from the unmounted component detection unit is mounted. It is preferable to notify the cell controller that controls the machine.

The cell controller receives NC data indicating the relationship between the line control system or the part and the position of the channel in the part mounting where the part is mounted.
It is preferable to automatically generate new NC data in which the NC data is updated and the missing parts are deleted, and the new NC data is retransmitted to the component mounter.

The cell controller receives from the line control system NC data indicating the relationship between the parts and the position of the channel in the component mounter on which the parts are mounted, and updates the NC data when receiving the out-of-stock information and updates the missing parts. It is preferable to automatically generate new NC data related to the other channel in which the same component as the missing component is accommodated and retransmit the new NC data to the component mounter.

The equipment includes a parts shelf in which the parts are stored, and a parts setting unit that takes out the parts from the parts shelf and sets them in the product. The parts shelf displays the storage position of each part as necessary, The setting section displays the relationship with the parts set for each channel in which the product is stored, as necessary, and the line control system needs to change the relationship between the parts to be put into the channel and the channel. At some time, it is preferable to display the position of the part that needs to be changed on the part shelf and the position of the channel on the part setting unit.

The line control system has an NC data memory that stores NC data regarding the parts to be mounted for each piece of equipment, and at least two pieces of equipment have the same specifications and are the same.
It is controlled by NC data, and when the line control system corrects the NC data for one of the equipment having the same specifications, it is preferable to immediately reflect the correction to other equipment having the same specifications.

The line control system is equipped with a dump file that dumps the state at the time of the work interruption when the work is interrupted in the middle of the lot and the system operation is terminated, and after the system is restarted, the work held in the dump file is restarted. It is preferable to be able to restart.

The line control system preferably collects the status of each piece of equipment via the cell controller and informs each cell controller of the status of the entire piece of equipment.

It is preferable that the line control system includes a logging file that accumulates the operation results collected in real time, and the contents of the logging file can be reproduced on the monitor screen at a later date.

The line control system preferably manages the manufacturing progress of the product and displays the location of the product on the graphic screen by inputting the product name.

[Brief description of drawings]

FIG. 1 is a system configuration diagram of a unit assembly line control system applied to the present invention, FIG. 2 is a configuration diagram showing a functional outline of the cell controller shown in FIG. 1, and FIGS. 3A to 3C are present inventions. 4A to 4D are block diagrams showing functions of the line control system shown in FIG. 1, and FIG. 5 is a block diagram showing an outline of scheduling according to an embodiment of the present invention. FIG. 6, FIG. 6 is a diagram showing an example of a work process, FIGS. 7A and 7B are diagrams showing a work line table in the conventional method, and FIG. 8 is a method for determining a product loading sequence according to an embodiment of the present invention. FIG. 9 is a flow chart for explaining, FIG. 9 is a conceptual explanatory view of grouping in the method shown in FIG. 8, FIG. 10 is an explanatory view of grouping procedure in the method shown in FIG. 8, and FIG. 11 is shown in FIG. Hand of product array in the way Explanatory diagram, FIG. 12 is a block diagram of a product input sequence determination device that can be used for carrying out the method shown in FIG. 8, FIG. 13 is a flowchart of the main routine in the method shown in FIG. 8, and FIG. A flowchart of the grouping routine in the method shown in FIG. 8, FIG. 15 is an explanatory diagram of the grouping processing in the method shown in FIG. 8, and FIG. 16 is a diagram showing a work line table by the method shown in FIG. FIG. 17 is a block diagram showing another example of the work process, FIG. 18 is a diagram showing input jobs and man-hours in the work process of FIG. 17, and FIG. 19 is a conventional simulation result by the man-hour of FIG. FIG. 20, FIG. 20 is a flow chart showing a simulation method of job processing time according to an embodiment of the present invention, FIGS. 21A to 21C are diagrams showing an example of a system configuration for implementing the method of FIG. 20, and FIG. Used in Figure 20 FIG. 23 is a diagram showing a configuration example of the processing history table, FIG. 23 is a diagram showing a configuration example of the free time management table used in FIG. 20, and FIG. 24 is a diagram showing a configuration example of the input job table used in FIG. FIG. 25 is a diagram showing a configuration example of the moving man-hour table used in the method of FIG. 20, FIG. 26 is a flowchart showing the operation of the simulation processing unit shown in FIG. 21, and FIG. 27 is the method of FIG. Figure 28 shows the process route applied to the process, Figure 28 shows the transition of the processing history table and free time management table shown in Figures 22 and 23, and Figure 29 shows the simulation results by the method of Figure 20. FIG. 30A to FIG. 30C are diagrams for explaining rescheduling in consideration of work in progress according to the embodiment of the present invention, and FIG. 31 is a diagram for explaining scheduling for avoiding equipment in failure according to the embodiment of the present invention. Figure 32 shows the implementation of the present invention. FIG. 33 is a diagram of a simulation result showing a comparison between a schedule and an actual result, FIG. 33 is a diagram showing a delay with respect to the schedule in FIG. 32 and its cause, FIG. 34 is a diagram of FIG. FIG. 35 is a diagram for explaining the execution schedule when there is an express item according to the embodiment of the present invention, and FIG. 36 is a diagram showing a model of a line system applied to the embodiment of the present invention. , FIG. 37 is a diagram for explaining the line system of FIG. 36, FIG. 38A is a diagram for explaining a control system of a conventional automated guided vehicle, and FIG. 38B is a diagram for explaining a process route of a product of a conventional example, FIG. 39A is a diagram for explaining the control system of another conventional automated guided vehicle, FIG. 39B is a diagram for explaining the process of the product of another conventional example, and FIG. 40 is an automated guided vehicle according to an embodiment of the present invention. Fig. 41 is a diagram for explaining the control system of Fig. 41, Fig. 41 is the control system of Fig. 40. FIG. 42 is a diagram for explaining the control system in the system, FIG. 42 is a diagram for explaining the schedule management table in FIG. 41, FIG. 43 is a diagram for explaining the process route management table in FIG. 41, and FIG. 44 is in FIG. FIG. 45 is a diagram for explaining the sensor monitoring process, FIG. 45 is a diagram for explaining the bar code reader monitoring process in FIG. 41, FIG. 46 is a diagram for explaining the work plan according to the embodiment of FIG. 41, and FIGS. 47A to 47O. 41 is a diagram for explaining the transition of the schedule management table in the embodiment of FIG. 41, FIG. 48 is a diagram showing a general configuration of a component mounting machine, FIG. 49 is an explanatory diagram of a conventional component mounting method, FIG. FIG. 51 is an explanatory view of a component mounting method according to an embodiment of the present invention, FIG. 51A is a diagram illustrating a conventional component mounting method, FIG. 51B is a view illustrating a component mounting method according to an embodiment of the present invention, and FIG. Is the parts specification management table in Fig. 50. FIG. 53 is a diagram showing a configuration example of the channel management table in FIG. 50, FIG. 54 is a diagram showing a configuration example of the NC data management table in FIG. 50, and FIG. FIG. 50 is a diagram showing a configuration example of a NC data previous transmission channel table in FIG. 50, FIG. 56 is a diagram illustrating a shortage management system according to an embodiment of the present invention, and FIG. 57 is an operation of the line control system in FIG. 58, FIG. 58 is a diagram showing the temporal change of the contents of each table in FIG. 50, FIG. 59 is a diagram for explaining the display of setup change instructions in the system of FIG. 56, and FIG. 60 is a diagram of the present invention. 56 is a diagram for explaining the reference of CAM data in the system of FIG. 56 according to the embodiment, FIG. 61 is a diagram for explaining the centralized management of the manufacturing situation in the system of FIG. 56 according to the embodiment of the present invention, and FIG. Figure 56, according to an embodiment of the present invention. Illustration of location and progress display function of the product in the system, 63 figures according to an embodiment of the present invention, is a diagram illustrating a logging manufacturing results in the system of FIG. 56.

[Best mode for carrying out the invention]

Like reference numerals refer to like parts throughout the drawings.

FIG. 1 is a configuration diagram of a unit assembly line control system as a manufacturing control system applied to the present invention. In the drawing, a cell controller 2-1 for each equipment 1-1, 1-2, 1-3, ..., 1-N such as a component mounting machine, a rack storage, a transfer device, ..., 2-3, ... , 2-N are installed, and the cell controller controls the corresponding equipment, collects manufacturing results,
Provide information services to workers. However, the cell controller does not need to be connected to the equipment on a one-to-one basis, and one cell controller may be provided for a plurality of equipment. These cell controllers are connected to the line control system 3 by a communication line such as (Local Area Network) LAN. The transport means 4 (hereinafter, referred to as an unmanned transport vehicle or a self-propelled vehicle) such as an unmanned transporter is controlled by the cell controller 5 and transports an article to be put into the facility or an article to be discharged from the facility.

FIG. 2 is a block diagram showing an outline of one function of the cell controller shown in FIG. As is clear from the figure,
The cell controller 2 controls the rack 11 and the component mounter 14 supplied from the automated guided vehicle 4, moves the required rack by the conveyor 15 and places it on the lifter 16, and the pusher 12 mounts the desired printed board 13 onto the component. Send to mounting machine 14.
In the component mounter 14, necessary components are mounted on the printed board 12, and the rack is ejected via the conveyor 15 returned to the rack 11. Each cell controller has the following functions.

Rack supply to and discharge from insertion machines and mounting machines in cooperation with automated guided vehicles Recognition of printed board types in racks Insertion machine and supply and discharge of printed boards to mounting machines NC data insertion machine managed by line control system , Transfer to mounted machine Transfer of manufacturing record to line control system Control of automated guided vehicle Rack management in storage and control of storage FIG. 3A is a system applied to a printed board assembly line as an embodiment of the present invention. It is a block diagram. First, the hardware configuration and main functions will be schematically described with reference to FIG. 3A.
The line is a plurality of insertion machine lines that automatically insert ICI 4, axial lead parts (AX) 14, radial lead parts (RD) 14, and a plurality of mounting machines 32 and rack storage 37 that automatically mount surface mount parts (SMD). It is composed of an automatic guided vehicle 4. These are cell controllers 2-1 to 2-
It is managed and controlled by N. These sensor controllers are connected to the line control system 3 by a LAN, and the line control system 3 collectively manages the transferred results. Also, NC data is line control system 3
It is centrally managed in the above database, and each of the cell controllers 2-1 to 2-N can reflect corrections and additions in all the automatic machines having the same specifications by referring to this database by the server function. In addition to the above, the line control system 3 has a function of creating a schedule for one week and evaluating it, a function of creating an execution schedule for one day in consideration of work in progress and equipment failure, and an unattended operation according to the execution schedule. Control of transport vehicles and monitoring of results, etc.
It has a function to support manufacturing on schedule and a function to aggregate and analyze manufacturing results. As shown in the figure, the sensor controller 2-1 controls the surface mount technology (SMT) L _n line including the printing machine 31, the mounting machine 32, and the reflow 33, and the cell controller 2-2 controls the IC, ( Axial lead parts) AX, (Radial lead parts) RD, etc. are used to control the inserter line that inserts parts according to the type of part. The cell controller 2- (N-1) is the dispenser 38, the mounting machine. Surface mounting technology (SM
T) The L ₁ line is controlled, and the cell controller 2-N controls the rack storage 37 for storing the completed printed board.

The line control system 3 manages the cell controllers 2-1 to 2-N as a whole, and as shown in the figure, weekly planning, weekly planning evaluation, daily execution planning,
It manages automated machines and self-propelled vehicles (automated guided vehicles), monitors line operation status, and gives work instructions for status changes. All of these functions can be displayed on the display. In FIG. 3B, a daily execution plan is displayed as an execution schedule inquiry, and it is possible to centrally monitor which product is started by which automatic machine at what time. The line operation status monitor is displayed as line monitor operation status details. In the line monitor, IC _S1,, IC _S2 ,
IC _S3 , AX _S1 , AX _S2 , RD _S1 , RD _S2 are the component mounters shown in Fig. 2.
There are 14 monitors, provided for each type of component. By observing the position of the rack 11 shown on the monitor of each mounter 14, the position of the rack at present can be centrally monitored. In addition, in the operation status details, the number of which product is currently processed by which automatic machine is displayed in real time. In Fig. 3C, the planned evaluation radar chart and the operating status by automatic machine are displayed. The planned evaluation radar chart displays evaluations for one week for various factors such as the delivery date achievement rate, line operation rate, setup frequency, overtime hours, lead time, and line balance. In the operating status display for each automatic machine, the occupation time of the job in each automatic machine is shown for each line, and the operating rate of the automatic machine is displayed.

4A to 4D are block diagrams illustrating various functions of the line control system shown in FIGS. 1 and 3A.

In FIG. 4A, the weekly schedule creation process 401
Creates a one-week schedule based on the CAM data 402 and the order data 403, and stores it in the weekly schedule memory 404. Here, the weekly schedule refers to the advance prediction of the line in consideration of the load of the line, the operating rate, etc., and is not particularly limited to the schedule of the period of 7 days. The schedule evaluation process 433 analyzes the created schedule and displays the result on the screen. When the line manager determines that he is satisfied with this schedule, he activates the line management database creation process 407. If not satisfied, change parameters such as line distribution method and lot division, and restart the weekly schedule creation process.

The data in the weekly schedule memory 404 is exchanged by the line management database creation process 407, and the order management memory 416 (FIG. 4C) and the rack management memory 417 are exchanged.
(Figure 4C).

The data in the result data memory 405 is used by the order consumption process 434 to erase the progress information of the order data 403 and used by the daily report output process 435 to print the daily operation report.

The NC data creation process 431 converts the data in the CAM data memory 402, which holds the component mounting information on the printed board, into the NC data unique to each mounting machine, and the NC data management memory 40
In addition to being stored in 9, the component setting information for the component channel of the component mounter 14 (FIG. 2) is created and stored in the component channel data memory 437 (FIG. 4B).

In FIG. 4B, a communication process 408 for each mounter 14
Exchanges events such as product input / discharge errors, error recovery, etc./actual data and NC data with the cell controller 2 of the corresponding product type, and causes an event in the result management process 412 (Fig. 4C).・ Send actual data.

In FIG. 4C, the performance management process 41 saves the operation status in 411 at the end of the operation of the line control system, and saves the operation status save memory 411 at the start of the line control system.
Capture the data in. The data created in the performance management process 412 is the order management memory 416, rack management memory 4
17, schedule management memory 410 order, rack,
Used to update the progress of the schedule,
It is stored in the logging file 413. Logging file 4
The data of 13 is passed to the line monitor process 414, the operating status is displayed by the line monitor 415, and also passed to the actual data creation process 418. The actual data creation process 418 uses this data and the order management memory 416.
Based on the order progress information from the rack management memory 417 and the rack progress information from the rack management memory 417, the performance data is created and stored in the performance data memory 405. The execution schedule creation process 420 creates an execution schedule based on the rack management data and the express instruction, and the schedule management memory 41
0 stores execution schedule information based on the data from the performance management process 412 and the data from the execution schedule creation process 420.

As shown in FIG. 4D, the rack management process 419 receives information on the number of printed boards per rack and the printed board type from the rack management memory 417 (a), and the rack storage system (cell controller) 2-N (third) (See FIG. 3A) (b), and the above information is displayed.
7 is displayed (c), and when the rack in which the printed board is actually stored is stored in the storage 424, the bar code reader 4 associates the contents with the bar code 425 of the rack.
26 and feed back to the rack management memory 417 (d, e, f). In the figure, a, b, c, d, e and f indicate the order of signal flow. The self-propelled vehicle control process 421 controls the self-propelled vehicle through communication with the automated guided vehicle system (cell controller) 5 based on the data from the rack management memory 417 and the schedule management memory 410. Schedule performance comparison process
422 receives the data from the schedule management memory 410, compares the schedule with the actual results, and displays 423
To be displayed.

The outline of the processing will be described step by step along the data flow in the present invention shown in FIGS. 4A to 4D.

[1] Weekly schedule creation Next week 1 based on the order information in the order data memory 403 and the CAM information in the CAM data memory 402 on the weekend of the previous week.
A weekly schedule for a week is created by the weekly schedule creation process 401. The purpose of this scheduling is to allocate delivery to multiple facilities with the same specifications by observing delivery dates and balancing the load between facilities and lines to minimize the number of setups, and then evaluate the scheduling results. , To take proactive measures. Therefore, here we will first rank the express items according to the closeness of delivery, those that should be introduced as soon as possible, and those that may be introduced at any time. In scheduling, the delivery date has the highest priority, but if there is an express item, the express item is processed with priority over the delivery date of a normal product. In addition, although there is a certain margin in the delivery date of normal products, for express items, do you want to shorten the delivery date margin?
May be zero. Then, each group is further grouped under the same setup condition, the man-hours are calculated, and the equipment is distributed to the same equipment. A post-delivery performance, line availability, setup rate, line balance, average lead time, etc. after performing a loading simulation (the simulation method will be described in detail later) according to the equipment and loading sequence determined in this way It is evaluated by and shown in the radar chart (Fig. 3C). In addition, there is a function that can be given as a parameter such as the method of distributing to equipment and the method of lot division, and the operator can change these parameters to create multiple schedules and judge from the evaluation results to select the optimal schedule. it can. In addition, it is possible to anticipate uneven load and delivery delay in advance, so it is possible to take outsourcing measures in advance.

[2] Storing racks in storage The worker stores the printed boards of the products scheduled according to the weekly schedule in the rack storage 37 for each rack that is a unit of assembly and transportation. At this time, the cell controller 2-N of the rack storage 37 reads the bar code assigned to the rack and associates it with the contents of the rack, and the associated information is notified to the rack management process 419 in the line control system 3. , Rack management memory 417.

[3] Creation of Execution Schedule In the execution schedule creation process 420, the products scheduled to be supplied for one day today are cut out according to the scheduled date of supply according to the weekly schedule. If there are products that cannot be put on schedule due to limited items or missing items, change the launch schedule. Then, these new inputs are added to the undigested portion (including those in process) of the execution schedule of the previous day to create an execution schedule for one day (Fig. 30A to Fig. 3A).
(See Figure 0C). The purpose of this execution scheduling is to increase the operating rate and minimize the number of setups. For this reason, we prefer to minimize the number of setups from a process with a high load, thereby reducing the effect of setups on the work time (see Figures 6 to 16). And will be detailed later). Further, in cooperation with the cell controller 14, the performance management process 412 constantly monitors the failure status of the equipment, and avoids the equipment in failure to perform scheduling. In addition, by performing a recursive simulation of the processing conditions of the jobs after the next process, an accurate simulation is performed by using a job processing time simulation method that considers the interrelationship between processes (Figs. 17 to 29). ) Will be described in detail later).

[4] The self-propelled vehicle control process 421 controls the automatic guided vehicle according to the schedule (detailed later with reference to FIGS. 36 to 47O).

[5] Manufacturing support in each cell The barcode attached to the rack carried by the automated guided vehicle in the order of loading according to the schedule is read by the cell controller 2, and the cell controller 2 stores the rack management memory in the line control system 3. By referring to 417, the contents of the rack are known, and the NC data of the product is also obtained from the NC data memory 409.
Then, the NC data is transferred to an automatic machine (component mounting machine 14) to start assembly. The loading / unloading of the rack, the loading / unloading of the printed board, and the error occurrence / recovery are reported to the line control system one by one by the cell controller and recorded. The line control system compares the schedule with the actual result, detects frequent occurrence of errors such as insertion errors and a large delay, and informs the operator how to deal with it from each cell controller according to the know-how of the line manager. In addition, failure information from the automatic machine is detected and re-schedule is urged if necessary (details will be described later with reference to FIG. 34). Know if it needs replacement. Therefore, when a setup change is necessary, a lamp is lit on a predetermined shelf of the parts shelf in which the necessary channel and the parts to be set there are stored, and the worker is informed (see Fig. 59). In addition, when the remaining number of parts is managed and the product is out of stock on the way, NC data changes such as channel change and cancellation are automatically performed (detailed later with reference to FIGS. 48 to 58). Also, if the work is stopped in the middle of a lot, the situation at that time can be restarted from the continuation when saved and restarted (see Fig. 61).

[6] Monitoring Results and error occurrences reported from each cell are centrally managed by the line control system 3. By displaying this on the graphic display 415, the situation of the entire line can be grasped at one place. In addition, these results are also passed to the schedule management memory 410 and used in the schedule result comparison process 422 for comparison and monitoring with the schedule and as a work-in-progress condition at the next scheduling.

[7] Achievement record / reproduction (see FIG. 63) Manufacturing results and error results are stored in the logging file 413 in order of occurrence time, and past results can be reproduced on the graphic display. In addition, the frequency and cause of errors, time required for recovery, operation, setup, ratio of waiting time, deviation from schedule, etc. will be totaled and displayed as a graph for consideration for improving production. In addition, we manage out of stock for each printed board,
The post-processing work will be simplified.

The line control system shown in FIGS. 4A to 4C has the following three main functions.

-Ability to create a schedule-Ability to support production according to a schedule-Ability to analyze production results Below is a description of each function in order.

[1] Function for Creating Schedule FIG. 5 is a block diagram showing an outline of scheduling according to an embodiment of the present invention. First, on a weekly basis, based on the manufacturing order information 403 and the CAM information 402, the weekly schedule is created in advance by the weekly schedule creation process 401 while considering the achievement of delivery date, improvement of equipment operation rate, line balance, and reduction of setup. Is created and stored in the memory 404, and an evaluation unit 51 for evaluating the created schedule based on the operating rate, the degree of achievement of the delivery date, and the like is provided. Prior to creating the weekly schedule, select from multiple conditions such as the method of determining the input sequence and the method of lot division.If the evaluation of the created schedule is low, the operator should change these conditions and reschedule. I can do it. This allows
You can create an optimal weekly schedule.

This weekly schedule is for grasping the schedule for the next week in advance and taking countermeasures, but in actual work, it may be misaligned due to work in progress on the previous day (leftover work in the previous day's work), occurrence of express goods, equipment failure, etc. Occurs. Therefore, a more precise schedule (execution schedule) for actual work for one day is created in the following procedure.

From the cell controller 2 of each facility, the communication process 408
In addition to grasping how far the execution schedule created last time is exhausted and the equipment that can not operate due to failure etc. based on the work record collected in real time, input for one day by invalidating the date determined by the weekly schedule Cut out the planned item again, schedule the current continuation, and update the schedule.

The following new methods are used in these schedulings.

Product input order determination method (setup time efficiency method), job processing time simulation method, scheduling method considering work in progress, scheduling method to avoid equipment in failure.

 Hereinafter, the method will be described in detail step by step.

Product input sequence determination method (Efficient setup time) A setup that occurs in a low-load process that causes a lot of waiting time has less effect on the work time than a setup that occurs in a high-load process. From the above, the total value of the work time of the products input for each process is determined, the priority order for minimizing the setup is determined, the items with the same setup conditions are grouped in the order of the process, and the input sequence is determined. This minimizes centrifugation at the completion time due to setup. A more detailed description is as follows.

In the field of electronic device manufacturing, when a plurality of products are processed (manufactured, processed, etc.) through a plurality of processes, processing conditions are set or changed in each process, that is, process equipment, in order to process different types of products. Preparations such as adjustment and material replacement may be required. In particular, it is necessary to change the processing conditions frequently when performing high-mix low-volume production. If the process of processing a plurality of products is a single process, the operation rate of the equipment can be increased by deciding the order of introducing the products so that the number of changes of the processing conditions is minimized. When the process of processing the product is a plurality of processes, it is not always easy to determine the input order of the product. For this reason, there is a demand for a method for determining the order of product introduction that can improve the operating efficiency of equipment when processing a plurality of products through a plurality of steps.

For example, as shown in FIG.
A case in which a plurality of products as shown in Table 1 are processed through A, B, C) in this order will be considered.

In Table 1, the working time has an arbitrary unit (for example, minutes), and the working time proportional to the number shown in the corresponding column is required when the product is processed by each process. For example, it has been shown that when a product is processed by the process B, the working time is three times as long as when the product is processed by the process A. In addition, two kinds of processing conditions (setup) are assumed in each process. For example, in process A, products and products can be processed under common processing conditions (A-1). Indicates that the processing conditions are different ((A-1) and (A-2)), so that it is necessary to change the processing conditions when shifting from the product processing to the product processing. It is assumed that one unit of time is uniformly required to change the processing conditions.

Fig. 7A shows a work line table when products are put in this order without considering the difference in processing conditions of each process. In the figure showing the work line table, the time represents the passage of the unit time described above. The hatched portion in the drawing indicates the period during which the processing conditions are set or changed, that is, the setup is being performed. As is clear from the figure, when the product input sequence is determined in the order of product numbers without considering the processing conditions, even though there are only two types of processing conditions for each process, the process A, B
It is necessary to change the processing conditions four times in step C and three times in step C.

FIG. 7B shows a work line table that minimizes the number of times the process condition is changed in the process A (1 time). In this case, process A
The common processing conditions do not mean that the processing conditions of the other steps are common, and the fact that the processing conditions of the process A are not common do not mean that the processing conditions of the other steps are not common. Normally, even if the number of times the processing conditions are changed in the process A is minimized, the number of times the processing conditions are changed in the processes B and C is not minimized.

As shown in FIG. 7A, when products are input in the order of product numbers, the time unit required to process all products through all steps is at least 31 units. On the other hand, as shown in FIG. 7B, when the products are put in such an order that the number of times of changing the processing conditions in the process A is minimized, the required time unit is 30 units. In this way, unless the processing conditions are effectively changed in each process, the processing conditions will become many kinds, especially when performing high-mix low-volume production.
The operating efficiency of the process equipment will be significantly reduced.

The method for determining the order of product injection according to the embodiment of the present invention was created in view of such problems, and an object thereof is to provide a method suitable for increasing the moving efficiency of equipment in high-mix low-volume production.

With reference to FIGS. 6, 7A and 7B and the processes and products shown in Table 1 in the specification, the problems of the conventional product order determination method and the points of focus of the embodiment of the present invention will be described.

In the process A shown in FIG. 7B, it is necessary to change the processing condition after the product is processed and before the product is processed. In addition, since the process B has a higher load than the process A and the process is clogged, the process B of the product ends only at the time 12 or later even though the process A ends at the time 10. Unable to process. Therefore, the product cannot be put into the process A until the product is transferred from the process A to the process B. Therefore, the processing conditions for processing the product in the process A can be changed during this waiting time. On the other hand, since the process is continuously performed in the process B, it takes time for changing the process condition, and the operating efficiency of the equipment is reduced accordingly. From the above consideration, it is possible to improve the operating efficiency of the equipment by preferentially minimizing the number of times of changing the processing condition of the process with a high load that does not cause a large waiting time, rather than the process with a low load that causes a large waiting time. It turns out to be effective above.

FIG. 8 shows a processing flow of the method of determining the order of product injection according to the embodiment of the present invention according to this principle.

The method of the present invention has several kinds of processing conditions according to the products to be processed, and sequentially processes a plurality of products by a plurality of steps that require a time required to change the processing conditions. This is a method of deciding the order in which the products are to be put in when carrying out.

Then, this method obtains the total value of the processing time for each process, and ranks the plurality of processes in descending order of the total value, and the process of the process in the order of the process according to the above order. A second step 82 for grouping products by conditions and a third step 83 for arranging the grouped products or products so that the processing conditions for adjacent product groups or products match as much as possible. I have it.

An example of a specific procedure in each step and the operation of the present invention will be described. First, the total value of processing time is calculated for each process. The results are shown in Table 2.

From Table 2, it can be seen that the load becomes lighter in the order of steps B, C, and A, and this order is the priority.

Next, according to this priority order, the processes B, C, and A are grouped in order according to the process conditions of the processes. The concept of grouping is shown in FIG. 9, and the grouping procedure is shown in FIG. When a product group consisting of products is grouped for each processing condition of the process B, a group of products having common processing condition (B-1) ,, and a group of products having common processing condition (B-2), Becomes Product,
When the groups of ,, and are further grouped for each processing condition of the process C, a group of products having common processing conditions (C-1) and a group of products having common processing conditions (C-2) are obtained. If a group consisting of products is further grouped according to the processing conditions of process A,
Become a product and a product. In this way, product grouping is repeated in the order of steps according to the priority order.

Thereafter, the grouped product groups or products are rearranged so that the processing conditions of the groups of products adjacent to each other in the horizontal direction of FIG. 10 or the processing conditions of the adjacent products match as much as possible. The results are shown in FIG. In FIG. 11, since the processing conditions of the process B are only two groups B-1 and B-2, the processing conditions adjacent to each other cannot match, so that the arrangement of this group is arbitrary. In the group of products grouped according to the processing conditions of the process C, (C-1), (C-2), (C-1),
Since the array is (C-2), this array is (C-1), (C-
2) Change to an array of (C-2), (C-1).
Similarly, for products grouped according to the processing conditions of the process A, (A-1), (A-2), (A-
2), (A-1), (A-1), (A-1), (A-
Arrange so as to be 2). The order of products arranged in this way is the determined order of input of products.

In this way, the product input order is determined, and the processing in each step for each product is performed according to this input order,
There is no fear that the operating efficiency of process equipment will decrease.

FIG. 12 shows a block diagram of a product injection order determination device used for implementing the product injection order determination method according to the present invention. This device includes an input device 121 for inputting data having the contents as shown in Table 1 for products, a display device 122 for displaying the determined product loading sequence, an input device 121 and a display device.
I / O circuit 12 with interface function for 122
3, CPU124 for calculating the total value of processing time, rearranging data, etc., and RAM1 for temporarily storing the calculation result etc.
25, ROM 126 that stores calculation programs, and I / O
A circuit 123, a CPU 124, a RAM 125, and a data bus 127 interconnecting the ROM 126 are provided.

The operation of this device will be described with reference to FIGS.
FIG. 13 is a flowchart of a main routine executed in the above device, and FIG. 14 is a flowchart of a grouping routine. The grouping routine is called directly from the main routine or recursively from the grouping routine. FIG. 15 is an explanatory diagram of the grouping process, and the priority order table 15 used in the main routine and the grouping routine.
5, product setup table 156, top setup table 157,
The contents of the sort table 158 and the head setup pointer 159 are conceptually shown. Note that the contents of the product setup table 156 are the same as the products and processes used in Table 1 for convenience of explanation.

The main routine will be described with reference to FIG. First, in step 131, the total value of the processing times is calculated for each process, and the priority order table 155 shown in Table 2 in which the processes are arranged in descending order of the total value is created. Next, at step 132, the top setup table 157 is cleared with blanks and the top setup pointer 159 is initialized. Then
In step 133, the priority table 155, the product setup table 156, the top setup table 157, and the top setup pointer.
The grouping routine is called with 159 as a parameter, and the grouping routine called in step 134 is executed. Finally, in step 135, the order of the product setup table rewritten by the grouping routine is set as the product loading order, and this is set as the display device 122.
Output to (Fig. 12).

The grouping routine will be described with reference to FIG. In this example, since the calculation procedure is simplified by recursively calling the grouping routine, the priority table 155 is an input parameter among the parameters used when calling the grouping routine, and the product setup table 156 and the top setup are used. The table 157 and the head setup pointer 159 are input / output parameters. First, in step 141, it is confirmed that neither the priority order table 155 nor the product setup table 156 is empty, and the process proceeds to step 142. In step 142, the product setup table is sorted according to the setup (processing condition) of the process B written at the head of the priority table 155 as shown in FIG. 9 for the processes B-1 and B-2, and the sorted table is displayed. Create 158. Next, at step 143, if there is the same setup as the setup indicated by the top setup pointer 159 in the top setup table 156, among the setups of the processes to be sorted,
Sort table 15 with the corresponding group at the top
Sort 8 Incidentally, in the range of the processing concerning the process B shown in FIG. 15, since nothing has been written yet at the position indicated by the pointer on the head setup table, the same setup cannot be made, so that step 143 is executed. Not not.

Next, in step 144, it is determined whether the content of the priority table 155 is larger than one record, that is, whether it is larger than one process. If it is determined that the priority table 155 is larger than one record, step 14
In step 5, if it is determined that the priority table 155 is not larger than one record, the process proceeds to step 153. In step 145, the priority order table 155 is rewritten as the second and subsequent records, that is, step C and step A in FIG. 15, and then in step 146, the product setup table 156 is cleared.

Then, in step 147, 1 is selected from the sort table 158.
Group by group (B-1 group, B-2 group)
Remove and repeat steps 148-152 to repeat
The grouping shown in FIG. 11 and FIG. 11 is performed. In FIG. 15, the group of step B-1 is taken out. In step 148, the head setup pointer 159 is incremented. Then, in step 149, the priority table 155
And the product setup table 156 for one group extracted from the sort table 158 and the top setup table 157.
And the head setup pointer 159 as a parameter, the grouping routine is recursively called and executed.
Note that the grouping routine is also called sequentially until the judgment in step 144 is negative even in the recursively called grouping routine.

If the determination in step 144 is negative, the process proceeds to step 153 and the sort table 158 is set to the product setup table.
After rewriting to 156, the grouping routine is exited and the process proceeds to step 150. In step 150, the top setup pointer in the top setup table indicates the setup of the process written at the top of the priority table of the last product in the table output from the grouping routine (product setup table in that grouping routine). Write in position. Next, in step 151, after decrementing the leading setup pointer, step 15
In step 2, the table output from the grouping routine (the product setup table of the grouping routine) is sequentially added to the product setup table of the calling grouping routine, that is, the product setup table cleared in step 146.

The product setup table finally obtained in this manner is the product loading sequence as described in the main routine. In the illustrated example, the product loading sequence is as shown in FIG.

According to the procedure described above, the product loading sequence similar to that described with reference to FIG. 11 is determined. The work line table in this case is shown in FIG. 16 according to the rules in FIGS. 7A and 7B. According to this embodiment, the time required for all the treatments is 28 units, which is 10% shorter than that shown in FIG. 7A and 7% shorter than that shown in FIG. 7B. Can be achieved. Although it cannot be said that the effect of shortening the processing time is remarkably large in this embodiment,
When there are many products and processes, the rate of shortening the processing time can be further increased.

The first reason for applying the recursive program is to make it a general-purpose program for the process path. That is,
The same program can be used for any route and any number of routes. The second reason is that when there are many products and processes, by executing a recursive program as in this embodiment, a relatively small amount of calculation processing is sufficient, and the programs and tables can be made permanent. This is because the storage capacity of the memory for temporarily or temporarily storing is small. For example, a simple device can be configured as compared with a case where a pattern of all throwing orders is simulated and the most efficient pattern is found.

By applying the method or apparatus described in this embodiment to, for example, a device for automatically inserting electronic components into a printed wiring board in the field of electronic device manufacturing, manufacturing workability is improved and production efficiency is improved.

As described above, according to the embodiment of the present invention described with reference to FIG. 6 to FIG. 16, it is possible to provide a method for determining the order of product introduction suitable for increasing the operating efficiency of equipment in high-mix low-volume production. There is an effect that it becomes possible.

Job processing time simulation method (see Figures 17 to 29) In this method, a table that manages the free time corresponding to each process, a table that retains the history of jobs processed in that process, and its history Provide an area to manage the latest address of the table. The input job has a process route and man-hours in each process as information. In addition, a table is provided for considering the movement time between steps. Then, for each job, the input time, the end time, and the discharge time to the next process obtained by recursively simulating the next process according to the process route are simulated and stored at the latest address in the history table. By repeating this, an accurate simulation can be performed in consideration of the front-back process.

 A more detailed description is as follows.

When multiple jobs are processed by walking between multiple processes connected by automatic transportation means (for example, when a product is transported by a conveyor and processed by several machine tools). (Conceivable), it is very difficult to manually simulate an appropriate job input time and time allocation in each process.

As one of conventional simulation methods, there is a load pile method. In this method, jobs are piled up before the next process and sequentially input. In this method, the mutual relationship between jobs and processes is not taken into consideration, and accurate simulation cannot be performed.

Next, consider the simulation. For example,
Consider the case where the job shown in FIG. 18 is submitted to the process path model shown in FIG. The process path model shown in FIG. 17 is composed of process A and process B. In FIG. 18, four types of input jobs are JOB1 to JOB4, and the man-hours of the processes A and B of each job are as shown in the figure. For example, JOB1 requires 5 man-hours in process A and 10 man-hours in process B.

First, JOB1 can be input in the order of process A → process B without any problem, and as shown in FIG. 19, the time is 0 to 5 in process A, and the time is 5 to 15 in process B. Next, regarding JOB2, at the time 5-8 after JOB1 is completed in process A,
In process B, JOB1 is in work, so wait until JOB1 ends, and the time becomes 15 to 20. That is, JOB2 is kept waiting in the process A from time 8 to 15.

Therefore, JOB3 cannot be input to the process A until time 15. From the above, JOB3 is time 15-2 in process A
5, the time is 25 to 28 in the process B. Next, for JOB4, there is no processing in process A and it is immediately input to process B. However, since the required man-hour is 4, time 0-5, 20-25 and 28
Although it can be input to any of the following points, it can be assigned to times 0 to 4 if there is no particular restriction on the input time.
As a result, the final simulation result is as shown in FIG.

In the relatively simple example shown in FIGS. 17 to 19, the simulation can be manually constructed as described above, but the process path model becomes complicated and the number of input jobs increases. If this happens, manual simulation becomes impossible.

The job processing time simulation method according to the embodiment of the present invention is provided in view of such a problem, and the job processing time simulation method is capable of accurately performing the job processing time simulation in a short time. Is intended to provide.

FIG. 20 is a flowchart showing the principle of the job processing time simulation method according to the embodiment of the present invention.
In FIG. 20, in the present embodiment, in step 201, a process history table for managing the job name, input time, end time and discharge time for each process and a free time management table for managing the free time of the process are provided. In step 202, the job name, the time when the corresponding job occurred,
The job is extracted from the input job table in which the route and the man-hours are registered, and the job name, the time of occurrence, the route and the man-hour are delivered to the simulation processing unit 217 (Fig. 21C), and the number of processes is based on the information delivered in step 203. Then, the simulation process is recursively performed to fill the process history table and the free time management table so that they do not contradict each other, and steps 202 and 203 are repeated for the number of jobs.

That is, a process history table that manages the job name, submission time, end time, and ejection time for each process and a free time management table that manages the free time of the process are provided, and these tables are inconsistent for each submitted job. We will make up for it by simulation processing so that it will not occur. Accordingly, the simulation of the job processing time can be performed accurately and automatically in a short time without manual work.

21A to 21C are diagrams showing a system configuration example for implementing the present invention. In FIGS. 21A and 21B, 21
1 is a processing history table that manages the job name, input time, end time, and discharge time, 212 is a free time management table that manages the free time of the process, and 213 functions to indicate the latest address of the processing history table 211. The latest address management unit.

In FIG. 21C, 214 is a job input table, and 215 is a transfer man-hour table.

FIG. 21C is a processing unit that simulates the job processing time based on the contents of these tables 211-215, a job extraction processing unit 216, a simulation processing 217,
The table update processing unit 218 is provided.

FIG. 22 is a diagram showing a configuration example of the processing history table 211. As illustrated, the table 211 stores a job name, a job submission time, a job end time, and a job ejection time. Generally, after the job is finished, the job cannot be discharged to another process immediately, so the end time does not always match the discharge time.

FIG. 23 is a diagram showing a configuration example of the free time management table 212. In the first state, the start time is 0 and the end time is ∞, which are all free times.

The processing history table 211 shown in FIG. 22, the free time management table 212 and the latest address management unit 213 shown in FIG.
Is provided for each process. For example, a process history table 211, a vacant time management table 212, and a latest address management unit 213 are provided for each of process A and process B shown in FIG.

FIG. 24 is a configuration example of the input job table 214 in which the input job name, the generation time of the input job, the route, the number of man-hours, and the like are stored, and FIG. 25 is the configuration of the transfer man-hour table 215 which stores the transfer man-hours between processes. It is a figure which shows an example. The number of man-hours in each process is stored for each job name. For example, as shown in FIG. 24, JOB1 has ten man-hours in process A, five man-hours in process B, and process C.
Then, 10 man-hours are required respectively. Since the occurrence time in the figure may be limited depending on the job, the occurrence time is stored in that case. In the example of the figure, all are 0 in the sense that there is no restriction on the time of occurrence. This input job table must be completed in advance before performing the simulation.

In the moving man-hour table 215, as shown in FIG. 25, for example, the moving man-hour between the process A and the process D is the required man-hour "2" at the intersection of A and B.

In FIG. 21, the contents of the input job table 214 are input to the job take-out processing unit 216, and the job, generation time, route and man-hour are extracted for each job. The extracted information is
It is passed to the simulation processing unit 217. The simulation processing unit 217 also stores the contents of the moving man-hour table 215.

Then, the simulation processing unit 217 first takes out the first one of the process paths given as the input values, and from the idle time management table 212 of the process, the empty space that can process the job earliest after the occurrence time. The time is found, and the input time and the end time when the time is input during the idle time are written in the processing history table 211. However,
Depending on when this job can be discharged to the next step,
It is necessary to change the input time in this process.

Therefore, from this tentative end time, only man-hours between the present process and the next process (this man-hour is calculated as the man-hour table 215).
The elapsed time is defined as the occurrence time, and the process and man-hours after the next process are recursively processed by the simulation processing unit 217 as the process and man-hours.
The available time for each process is determined one after another.

Here, after the simulation process in the next process is finished, the loading time of the latest process history table 211 of the next process is read, and the time traced back by the moving man-hours from that time is taken as the discharge time in this process, and attention is paid now. Check if you can enter within the free time. If it does not enter, the operation of finding the next free time is repeated.

In this way, since the input time, the end time, and the discharge time for one job are left in the process history table 211 of each process, the next table update processing unit 218 follows the contents of the process history table 211 and the free time management table 212 and the latest address. The latest address of the management unit 213 is updated.

FIG. 26 is a flowchart showing the operation of the simulation processing section 217. The flowchart shown in the figure illustrates the above-described operation in more detail. Upon receiving the input data, in step 261, the free time of the process written at the beginning of the process path is sequentially fetched from the free time management table 212, and the following sequence is repeated. First, the job name is written in the latest address of the process history table 211 of the leading process (step 262). Next, the later one of the job occurrence time and the idle time start time is set as the submission time and is written in the latest address of the process history table 211 of the first process (step 26).
3). Next, the time when the man-hours of the leading process have elapsed from the input time is written as the end time in the latest address of the processing history table 211 (step 264).

Next, it is confirmed by referring to the free time management table 212 that the end time obtained in step 264 does not exceed the free time end time (step 265). After checking, check whether the job has the next process (step
266). If there is a next process, perform a simulation for the next process recursively based on the input data (step
267).

After the recursive simulation, subtracting the man-hours from the input time written in the latest address of the process history table 211 of the next process is set as the discharge time of the latest address of the process history table 211 of the first process (step 268). Check that the calculated discharge time does not exceed the free time end time in the free time management table 212 (step 269),
If it has not exceeded, a completion flag is set (step 270).

When there is no next process in step 266, the process history table 21 is set with the end time of the first process as the discharge time.
Write to 1 (step 271) and set a completion flag (step 272). Such processing is performed for all the steps of one job, and when the processing of all the steps is completed, the information regarding the next job is received as input data and the same processing is performed again.

Next, consider a case where the present invention is applied to a specific job. Consider a case where JOB1 to JOB5 written in the input job table shown in FIG. 24 are input to the process path shown in FIG. It is assumed that FIG. 25 is a table showing moving man-hours when moving between the respective processes of FIG. 27. FIG. 28 is a diagram showing transitions of the processing history table 211 and the free time management table 212 when these jobs are sequentially simulated. In the figure, ST indicates the input time, ET the end time, and OT the discharge time.

(1) Initial state All the free time management tables 212 are changed from 0 to ∞, and nothing is written in the processing history table 211. Therefore, the latest address in each step is all 1 as shown in FIG.

(2) Input of JOB1 Since the number of man-hours in the first process A is 10 and the free time is 0 to ∞, the input time of the process history table 211 is 0 and the end time is 1
Set to 0. Here, in order to determine the discharging time, it is necessary to determine the charging time to the next step B shown in FIG. Therefore, referring to the moving man-hour table 215 of FIG. 25, the moving man-hour 1 between A and B is added to the end time 10 of the process A at time 11
With the occurrence time as the generation time, the simulation after the process B is performed. Since the man-hour of the process B is 5, and the free time is 0 to ∞ at the beginning, the input time is 11 and the end time is 16.

Similarly, in order to determine the discharge time in the process B, C of the next process is simulated, and the transfer man-hour is 2 because the input time is 1
8 and the man-hours are 10, so the end time is 28. Process C is JOB1
Since it is the final process, the end time is the discharge time as it is. Since the charging time in step C is determined, the discharging time in step B and subsequently the discharging time in step A are determined. As a result, as shown in FIG. 28, the free time of each process after the input of JOB1 is 10 to ∞ for process A, 0 to 11 and 16 to ∞ for process B, and 0 to 18 and 28 to ∞ for process C. , Change D
Goes from 0 to ∞.

(3) Input of JOB2 Free time of the first process A after JOB1 is completed is 10 to ∞, and the man-hour is
Since it is 20, the input time is 10 and the end time is 30. The free time of the process C after completion of JOB1 is 0 to 18 and 28 to ∞, the man-hour is 15, and the man-hour to move from the process A to C is 1, so that the input time is 31 and the end time is 46. Further, also in the next step D, the input time 47 and the end time 57 are similarly set. Since the end time in the process D is the discharge time as it is, the discharge time in the processes C and A is also the end time in each process.

(4) Input of JOB3 Free time of the first process B after completion of JOB2 is 0 to 11 and 16 to ∞
Since the man-hour is 10, the input time is 0 and the end time is 10
Becomes Next, considering the number of man-hours required to move to the next process A, the occurrence time is set to 11, and the process A is simulated. In the process A, after the completion of JOB2, the idle time is 30 to ∞ and the man-hour is 5, so the input time is 30 and the end time is 35. Also, since it is the final process,
The discharge time is also 35.

The number of man-hours transferred from the process B to the process A is 1, and the input time of the process A is 30, so the discharge time from the process B is 29,
Although the submission time of the process B is 19 and the idle time is up to 11, the job of the process B cannot be submitted during this idle time. Therefore, the simulation is performed again in the next free time 16 to ∞ of the process B. As a result, in job 3 28th
As shown in the figure, the input time of process B is 16 and the end time is 2.
6, the discharge time is 29, the input time of the process A is 30, and the end and discharge times are 35.

Hereafter, when JOB4 and JOB5 are simulated in the same way,
It becomes something like that shown in FIG. After the completion of all the simulations, the result of each process remains in the processing history table 211. If a Gantt chart is shown based on this result, the simulation result as shown in FIG. 29 can be obtained.

In the above-described embodiment, the case where the input job shown in FIG. 24 is applied to the process path shown in FIG. 27 has been described, but the present invention can be similarly applied to other than the above embodiment.

As described above in detail, according to the simulation method of the job processing time according to the embodiment of the present invention, the process history table for managing the job name, the input time, the end time and the discharge time for each process and the idle time of the process A free time management table that manages
By compensating these tables by simulation processing so that they do not contradict each other, the simulation of the job processing time can be performed automatically accurately and in a short time without manual work, and the practical effect is extremely large.

Rescheduling method considering work in progress (30A
(See Fig. And Fig. 30B) With this method, the lot start time, completed quantity, and lot end time are recorded and updated in real time for each product that is input, so that the in-process status at a certain point can be accurately grasped, It can be rescheduled from the continuation.

This rescheduling has already been briefly explained with reference to FIG. 5, but will be explained in more detail with reference to FIGS. 30A to 30C.

FIG. 30A is an example of a table showing schedules and results for the previous time. As can be seen from the figure, all the steps A, B, and C for the product a have been completed, and the step A for the product b has been completed, but the step B for the product b is half of the planned 20 pieces. Only 10 are finished, and the remaining 10 are in work. Further, the process C of the product b and the processes A and C of the product c are not yet started.

FIG. 30B is a diagram showing a product, a quantity, and a process of newly input.

In the present embodiment, these actual results and new inputs are the actual data memory 405 in FIG. 4A and the NC data memory 409 in FIG. 4B.
From these data recorded in real time, the table of the schedule and results for the previous time is updated, and the 30th item is displayed for products in work, unstarted products and new input.
A new schedule is created as shown in FIG. C and stored in the weekly schedule memory 404 in FIG. 4A.

As a result, the memory can be effectively used and a new schedule can be created smoothly.

Scheduling to avoid equipment that is out of order (see Figure 31) In this method, the operating status of each equipment is constantly monitored, and when there is an abnormal equipment that cannot operate when creating a schedule, the equipment is removed and scheduling is performed. . This method will be further described with reference to FIG.

In FIG. 31, it is assumed from the equipment status table that the equipment A-2 for executing the process A is abnormal and the equipment B-2 for executing the process B is also abnormal. Further, it is assumed from the table to be put in that it is known that, for example, 20 pieces of product a require 40 steps in the process B and 20 steps in the process C. It is also assumed that other products are scheduled to be introduced. In the setup column, indicates the setup pattern. In this case, create a schedule excluding abnormal equipment. As a result, as shown in FIG.
A schedule can be set to execute the product c for 20 man-hours.
It is possible to schedule 30 times to execute the product d by using 3. However, since the facility A-2 is abnormal, the schedule for using this is not created.

Similarly, for the process B as well, a schedule for using the facility B-2 is not created.

In this way, by performing scheduling while avoiding abnormal equipment in advance, it is possible to reduce the number of times alarms are generated and to smoothly mount components.

[2] Function for supporting manufacturing according to schedule In order to perform the work faithfully according to the schedule created by the method described in [1] above, the following functions are provided according to the embodiment of the present invention.

A function that compares the schedule and actual results to detect differences and instruct the line manager on how to respond (Figs. 32 and 33).
(See the figure) As shown in Fig. 32, there is a delay beyond the actual range with respect to the time when the event in the schedule changes, such as product input, end, discharge, start of setup change, end time, etc. If there is an error, the product's handheld time or equipment's operating time greatly exceeds the theoretical value, the frequency of error occurrence is abnormally high, or it takes too much time to recover the error. There are some differences that are difficult to achieve. In this case, as shown in FIG. 33, the cause is analyzed for each phenomenon and the line manager is notified in batch format or the operator is notified in real time.

In FIG. 33, the phenomenon is a delay in the start time and the end time of the job, and the cause thereof is the aftereffect of some delay that occurred before, or the decrease in work efficiency is determined by the analysis.

The phenomenon is an increase in the handheld time (standby time) in the equipment, which is caused by the failure of the carrier, the delay of other processes, and the like. For other phenomena, their causes are analyzed as shown.

With this function, the worker or the line manager can promptly take an appropriate response to the deviation of the performance from the schedule.

Function to detect equipment failure and reschedule (see Fig. 34) During execution of the schedule, for example, the cell controller 2
-2 detects alarm information from the equipment 1-2 and communication disabled (power cut etc.) state, the cell controller 2-2 analyzes this and if the failure is unrecoverable or takes a long time to recover, its cause If it can be confirmed, it is automatically rescheduled as if there is no such equipment. Further, if the cause cannot be determined by analyzing the alarm information or the communication disabled state, the operator is inquired whether or not rescheduling may be performed.

In this way, by detecting the failure of the equipment and rescheduling it while the schedule is being executed, the equipment 1-
No need to give an alarm every time at 2, and the line can be controlled smoothly.

Function for preferentially processing limited express items (see FIG. 35) Even if the product loading order determined by the embodiment described with reference to FIGS. 6 to 16 is limited to limited express items, for example, on the morning of the day. If there is a request such as that which must be completed in the middle, the priority flag is set for the product at the time of the request as shown in Fig. 35, and the product with the priority flag is set. You may make it process with the highest priority. Instead of setting the priority flag, the margin of the processing time of the express goods may be set to be smaller than or zero than the margin of the processing time of the normal products.

Vehicle control method according to execution schedule (36th
(Refer to Fig. 47O.) In this method, instead of transporting to the next process after completion of work, there is a carry-in (input) schedule for each fixed and the product that should come to the next process according to that schedule Is requested from the delivery destination, the product is matched at the delivery source, and then the delivery is performed, so that the automatic delivery according to the schedule is realized.

Recently, with the progress of automation and unmanned operation of various equipment, not only automation of equipment but unattended operation, products are transported between multiple equipment using an automated guided vehicle.
We are promoting automation and unmanned operation of the entire system.

FIG. 36 is a diagram showing a model of a line system for explaining this method. In the figure, a plurality of facilities 14 (A
To D) are arranged in the vicinity of the transfer route, and a rack loaded with a printed board from the input storage 361 or the unloader of other equipment is carried into the loader 364 of each equipment by the transfer vehicle 4, or from the unloader 365 of each equipment. It is discharged to the loader of another facility or the output storage 362 by the transport vehicle 4 via the transport path 363. The loader 364 is provided with sensors SA to SD for identifying the presence / absence of loaded products, and the unloader 365 is provided with bar code readers BA to BD for identifying finished products.

FIG. 37 is a diagram for explaining the control system for the automatic guided vehicle shown in FIG. 36. A plurality of facilities A to N are equipped with a sensor 371 for confirming the presence or absence of products on the loader and processing on the unloader. A bar code reader 372 for identifying the finished product is added.

Information from the sensor 371 and the bar code reader 372 is input to the line control system 3 (see FIG. 1), the equipment to be processed next is recognized, and the product from the line control system 3 is instructed by the instruction from the line control system 3. When the equipment is finished, and the processing by the equipment is completed, the unloader loads it onto the automatic guided vehicle and conveys it to the loader of the equipment for the next processing.

In such a processing system, there is a demand for an automatic guided vehicle control method that does not reduce the efficiency as a whole even when the processing time deviates from the scheduled time.

FIG. 38A is a diagram illustrating a control system of a conventional automated guided vehicle, FIG. 38B is a diagram illustrating a process of a conventional example product, and 39A.
FIG. 39 is a diagram for explaining a control system of another conventional automated guided vehicle, and FIG. 39B is a diagram for explaining a process of another conventional product.

FIG. 38A shows a control system for a conventional automated guided vehicle, and the process sequence of products a, b, c ... Is shown in FIG. 38B.

As shown in FIG. 37, the loader for loading products into the facilities A to N is provided with a sensor 371, and the unloader for carrying out products is equipped with a bar code reader 372.

In FIG. 38A, conventionally, first, the bar code reader 372 of the facilities A to N is monitored, and when the product is on, the next process of the product is confirmed. Next process sensor
When it is confirmed that the 371 is off, the product is transported.

For example, the product a shown in FIG. 38B is first processed in the equipment A, and then the unloader of the equipment A is loaded to the bar code reader.
At 372, the bar code is read, it is confirmed that the next step is the equipment B, and if it is confirmed that the product is not loaded on the loader of the equipment B, the product is transported to the equipment B.

FIG. 39A is a control system for another conventional automated guided vehicle. As shown in FIG. 39B, the product process is designated to move the product by time.

For example, looking at product a, the processing start time of No. 1
In 8.00, it is in the input storage St and is transported to the designated facility A. In No. 7, since the processing by the equipment A is completed at 8.40, the product a is transported from the equipment A to the equipment B. In this way, the timer is monitored, and when the scheduled time comes, the designated product is transported from the designated facility to the designated facility.

In the conventional example described with reference to FIG. 38A and FIG. 38B described above, the loader is checked for vacancy and immediately conveyed, so that the equipment can be operated efficiently, but the order of the products to be put into the equipment. Is not guaranteed.

Therefore, when the equipment performs the same processing for all products, there is no problem, but when the processing contents differ depending on the product and setup change is required, the optimum product loading sequence is decided in advance. It is necessary to put the product in accordance with it.

For example, in the work of inserting an IC into the printed board unit with the IC inserter, when the type of the printed board unit changes, it is necessary to change the IC type and change the control program, so the same work is performed continuously. It is important to ensure that efficiency is not compromised.

Further, in the conventional example described with reference to FIG. 39A and FIG. 39B, the product is conveyed according to a pre-scheduled time table, but if a deviation occurs in the processing time, a contradiction occurs or the time is changed. May be wasted.

In the method for controlling a self-propelled vehicle according to the embodiment of the present invention, as will be described in detail below, when a product is loaded in a loading sequence according to a schedule determined by each of a plurality of facilities, and a processing time deviation occurs. However, the equipment can be operated efficiently.

FIG. 40 is a block diagram illustrating the principle of the control system for the automatic guided vehicle according to the embodiment of the present invention.

In FIG. 40, A to N are a plurality of equipments, 4 is an automatic guided vehicle for unattended product transportation between the equipments A to N, and 41 is a product detection unit at the inlet of the equipments A to N. Yes, 3 is a line control system that controls the processing schedule of a plurality of facilities A to N and the automatic guided vehicle 4, and 42 is a plurality of facilities A
When the product detection unit 41 detects that there is no product in the input ports of ~ N, it is a transfer request generation unit that requests the transfer of the product to be received next.

 The operation of the system shown in FIG. 40 is as follows.

The product detection unit detects the presence or absence of products at the inlets of a plurality of facilities A to N.
If there is no product in the inlet, the transfer request generation unit 42 requests the transfer of the next product to be received, and the line control system 3 notifies the contents of the transfer request generated by the transfer request unit 42 and the completion of processing. When there is a product with a matching matching effect, by issuing a transfer command for the product to the automatic guided vehicle 4, even if the processing time of the product deviates from the scheduled time, the equipment A It is possible to efficiently operate ~ N.

The embodiment will be specifically described below with reference to FIGS. 41 to 47A to 47O.

FIG. 41 is a diagram for explaining the control system of the automated guided vehicle of the embodiment of the present invention, FIG. 42 is a diagram for explaining the schedule management table of the embodiment of the present invention, and FIG. 43 is a process of the embodiment of the present invention. FIG. 44 is a diagram for explaining the route management table, FIG. 44 is a diagram for explaining the sensor monitoring process of the embodiment of the present invention, FIG. 45 is a diagram for explaining the bar code reader monitoring process of the embodiment of the present invention, and FIG. The figure explaining the work plan of the Example of this invention,
47A to 47O are views for explaining the transition of the management table according to the embodiment of the present invention.

FIG. 41 is a diagram for explaining the method for controlling the automatic guided vehicle 4. In the line control system 3 described in FIG. 37, a schedule management table 41A for managing the work schedule of the product to be put into each facility is provided. , A pointer 41B indicating the latest schedule, a process path management table 42A for managing the process path and the current location of each product, and a transfer wait for avoiding duplication of transfer requests until the transfer is actually completed after the transfer request is transmitted. A flag 42B is provided. When the transportation waiting flag 42B is on, the transportation is in progress.

As in the conventional example, the equipments A to N are provided with the sensor 371 for the loader for loading the product and the bar code reader 372 for the unloader for carrying out the product. The sensor 371 and the bar code reader 372 for the equipments A through N are provided. Sensor monitoring process 43
A, monitored by the barcode reader monitoring process 44A,
From the result, the automated guided vehicle 4 is controlled by the automated guided vehicle control process.
Control at 45A.

FIG. 44 is a flow chart for explaining the operation of the sensor monitoring process 43A according to the embodiment of the present invention.

In FIG. 44, in the sensor monitoring process, the sensor 371 of each loader is constantly monitored (step 441). For example, the loader of the equipment A with No. 1 of the schedule management table 41A in FIG. If it is determined that there is a product (step 442), this loader is ready to receive the product.
A is checked to confirm that it is the product a, and the current location and process route of the product a are checked by the process route management table 42A (step 443).

If the current location is 0 (step 444), the product a is in the input storage (St) 361. Next, a transfer instruction to transfer the product a from the input storage 361 to the facility A is issued (step 445), and the transfer is executed. After the completion of transportation (step 446), the pointer 41B for the schedule management table is updated to No. 2 and the current location of the process route management table 42A is updated to 1 to indicate that the equipment A has the product a (step 447). Thus, the input storage (St) 361
The product a is conveyed from the loader to the loader of the equipment A.

Next, the pointer 41B for the schedule management table is the fourth
Since it is No. 2 in Fig. 2, equipment A requires product b. At this time, it can be seen from FIG. 43 that the product b is in the facility C because the current location is 1. If the conveyance waiting flag 42B corresponding to the equipment C is off and the product name read by the bar code reader 372 of the equipment C is b (step 448), the conveyance waiting flag 42B is turned on, and the equipment B is installed. A transportation instruction for transporting the product b is issued to A (step 449). After the completion of transportation (step 450), the pointer 41B is updated to No. 3,
The current location of the product b in the process route management table 42A is 1 to 2
Update to (equipment A) (step 451). Thus, the transfer of the product b from the equipment C to the equipment A is completed.

FIG. 45 is a flowchart for explaining the operation of the barcode reader monitoring process 44A according to the embodiment of the present invention.
The processed product cannot be conveyed to the output storage St only with the sensor monitoring process 44A in Fig. 4, so the product name is read with the barcode reader 372, and confirmed with the process route management table 42A. In the case of the output storage St, a transfer request is issued and the output storage St is transferred.

More specifically, Bar Code Reader Monitoring Process 44A
Constantly monitors the bar code reader of the unloader 365 (Fig. 36) of each facility (step 452), the conveyance waiting flag 42B corresponding to a certain facility is OFF, and the unloader of the facility has a product. In the case (step 453), the product name is read by the bar code reader 372, and the process route and the current location of the product are checked in the process route management table 42A (step 454). Then, if there is no process to be transported after the present location (step 455), the transport waiting flag corresponding to the equipment is turned on, and an instruction to transport the product from the equipment to the output storage (St) 362 is issued. When this transportation is completed, the transportation waiting flag corresponding to the equipment is turned off, and the current position in the process route management table 42A is updated to 0 (step 457).

FIG. 46 is a diagram for explaining the work plan of the embodiment described with reference to FIGS. 40 to 45, and it is planned which products the facilities A to D will process with the passage of time. ,
This is an example in which the products a, b, c, d, and e are processed by the facilities A, B, C, and D.

In Fig. 46, in the equipment A, the product a is processed from the time 8.00 to 8.40 and the product b is 8.40 as shown in Fig. 42.
To 8.50, and a work plan is created in which the product d is processed from time 8.50 to 9.00.

As for the facilities B, C, and D, the work plan is such that products are processed in the time zone shown in the figure.

47A to 47O are diagrams for explaining the transition of the work plan shown in FIG. 46 as a management table.

FIG. 47A shows the initial state. In the initial state, all pointers (shown in the figure) indicating the latest schedule point to the heads of the schedule management table and the process route management table, and the current location of the product in the process route management table is the input storage St.

At this time, since all the loaders are empty, an instruction to transfer the first product from the input storage St to each facility is issued according to the schedule.

Fig. 47B: The product is transported according to the above transport command, and the pointers in the schedule management table of each facility are No. 1 to No. 2.
Is updated, and the current position of the process route management table is updated from 0 to 1. The pointer in the schedule management table indicates that it has changed from the previous state.

FIG. 47C: Suppose that the loader of the equipment C becomes empty after a certain time has passed. At this time, the pointer of the schedule management table of the equipment C points to the product c. Therefore, looking at the current location of the product c in the process route management table, 1 indicates the first facility B on the process route.
When the product c arrives at the unloader, the transfer instruction from the equipment B to the equipment C is issued.

After the transfer is completed, the pointer of the schedule management table of the equipment C is updated from No. 2 to No. 3, and the current location 1 to 2 of the product c is updated. Figure 47C shows the updated table.

In the same manner, the processing of the product by each facility is promoted while checking the schedule management table and the process management table in the same manner.

As described above, according to the method for controlling a self-propelled vehicle according to the execution schedule according to the embodiment of the present invention, the work schedule for each facility is managed, and the input port from the product detection unit at the input port of each facility is managed. By issuing the transportation request based on the vacant information, even if the processing time of the product is deviated, the equipment can be efficiently operated as a whole.

In automatic assembly machines such as inserters and loading machines, a method of managing missing parts of the parts to be assembled and automatically correcting the insert data (see Figure 48 to Figure 58). By managing the remaining number of parts set for each channel by 2,
Automatically change and retransmit NC data when a part of a certain channel disappears and the channel is switched to another channel with the same part set, or when the part runs out. In addition, by managing the shortages in units of one product, it is possible to improve the efficiency of post-processing when parts are prepared.

 A more detailed description is as follows.

In the field of manufacturing electronic circuit devices such as printed wiring board units and ceramic circuit modules, component mounting machines 14 (see FIG. 2) such as component insertion machines and mounting machines are used for the purpose of improving production efficiency. It This type of component mounter is configured to mount components set in a plurality of channels at predetermined positions on a printed wiring board according to NC data. Since the amount of parts used varies depending on the type of parts, some channels may run out of parts in a short time, and some channels may run out of parts for a long time. For this reason, it is necessary to devise a device that enables long-term unmanned operation.

The general configuration and operation of the component mounter will be described with reference to FIG. The printed wiring board conveyed by the belt conveyor 15-1 is supplied to the component mounter 14 via the feeding / discharging device (pusher) 12, and the components set in the respective channels of the component setting section 542 are mounted on the component mounter. It is mounted on a printed wiring board at 14. The printed wiring board on which the components are mounted is sent to the next step by the belt conveyor 15-2 via the supply / discharge device 12a. The printed wiring board supplied to the component mounter 14 is identified by the barcode reader 541, the cell controller 2a operates based on this identification signal, etc., and the supply / discharge device 12a, the component mounter 14 and the component setting unit 542 are operated. The operation is controlled.

The conventional signal exchange of each component will be described with reference to FIG. Bar code reader 483 to cell controller 2a
To the component mounting machine 14, NC data is sent from the cell controller 2a to the component mounter 14, a mounting completion signal is sent from the component mounter 14 to the cell controller 2, and the sensor controller 2 supplies it. A supply / discharge command signal for the printed wiring board is sent to the discharge device 12a.

In the conventional control method for component mounters, etc., the function to set the same type of component in multiple channels and automatically switch to another channel where the same type of component is set when the component runs out Since there is no, there were the following problems. That is, in the unmanned component mounting system that automatically recognizes the printed wiring board by the bar code reader as described above and automatically replaces the NC data of the mounting machine every time the type of the printed wiring board changes,
A channel in which a large amount of parts is set runs out in a short time, and it is necessary to replenish the parts each time. If there is no component to be replenished, an error occurs at each step of mounting the component, and it is impossible to perform unmanned operation for a long time.

In this embodiment of the present invention, in view of such a situation, the same component can be set in a plurality of channels, and even if a shortage occurs, the shortage is managed for each printed board and automatically processed. It is an object of the present invention to provide a method for controlling a component mounter capable of continuing the above.

FIG. 50 is a block diagram showing the principle of this embodiment of the present invention, in which the components set in a plurality of channels are mounted according to NC data at predetermined positions on a printed wiring board that are successively supplied one by one. The configuration of the cell controller 2 that controls the mounting machine 14 is illustrated.

In FIG. 50, reference numeral 490 is a component specification management table, which stores the type and quantity of components to be mounted on the supplied printed wiring board.

A channel management table 491 stores the types and quantities of parts set in each channel, the quantity, and the channel in use.

Reference numeral 492 is an NC data management table, which stores the channel in which the component is set and the position information where the component is to be mounted for the component to be mounted on the supplied printed wiring board.

Reference numeral 493 denotes an NC data previous transmission channel table, which stores all or a part of NC data of the printed wiring board supplied immediately before the supplied printed wiring board.

Then, in the processing unit 495, the contents stored in the NC data management table 492 are updated according to the remaining amount of the components of each channel, the NC data is edited by the NC data editing unit 496, and the edited data is edited. The NC data is sent to the component mounter 14.

According to the above-described embodiment of the present invention, the above-mentioned tables are provided, and the stored contents of the NC data management table are updated according to the remaining amount of the parts of each channel. It becomes possible to set and automatically switch to another channel in which the same type of component is set when the component runs out.

The above tables 490-493 are the NC data memory 40 of FIG. 4B.
Stored in 9.

FIG. 51A shows an example of the relationship between channel numbers and component specifications (component types) in the conventional method, and FIG. 51B shows an example of the relationship between channel numbers and component specifications in the embodiment of the present invention. In the table, the lower case letters of the alphabet represent the parts specifications. As shown in the figure, conventionally, each type of component specification is assigned to each channel on a one-to-one basis, but in the embodiment of the present invention, the component specification a is assigned to a plurality of channels 1, 2, and 3. Parts specification b on 4,5, channels 10,11,1
Parts specifications g are assigned to 2,13.

 The above embodiment of the present invention will be described in more detail below.

In FIG. 48, in the embodiment of the present invention, a cell controller 2 according to the present invention is provided instead of the conventional cell controller 2a. The configuration and functions of the parts other than the cell controller 2 and the connection relationship between the cell controller 2 and other parts are the same as those of the conventional device, and therefore the description thereof will be omitted.

FIG. 52 shows an example of the stored contents of the parts specification management table 490. In this example, the parts required to assemble the printed wiring board are a, b, c, ... And their quantity is 30,20,1.
5, ...

FIG. 53 shows an example of the stored contents of the channel management table 491. In this example, for example, the part a is a channel (CH.) 1,
7 and 8, the part b is set only in the channel 3. The channel whose busy flag is "1" is busy, and the channel whose busy flag is "0" is not busy. The quantities of parts a of channels 1, 7, and 8 are 14, 9 and 7, respectively, and the total quantity of parts a is 30
It is consistent with the table in the figure.

FIG. 54 shows an example of the stored contents of the NC data management table 492. It is a list of the set channels and position information to be mounted for each component in the order of mounting from the top of the table. X and Y indicate the position coordinates of the part on the printed wiring board, and θ indicates the direction of the part. 7 parts a are required, but the first 6 of them are supplied from channel 1,
The last one is supplied from the channel 7.

FIG. 55 shows an example of the contents stored in the NC data previous transmission channel table 493. For example, a part of the NC data (type of component and channel in which the component is set) for the printed wiring board supplied immediately before the printed wiring board corresponding to the NC data management table shown in FIG. 54 is stored. Has been done.

FIG. 56 is a block diagram showing the configuration of a system for carrying out the out-of-stock process according to the present embodiment, in which the parts according to the present embodiment are extracted from the system shown in FIG. In FIG. 56, the component mounter 14 notifies the cell controller 2 of out-of-stock information indicating which channel has a missing part. Based on the data in the NC data memory 409 sent from the line control system 3, the cell controller 2 determines which part of the printed board of the channel is out of stock at that time, stores it in the out-of-stock management memory 583, and manually. The NC data, which is used to replenish parts and deletes missing parts, is automatically generated and retransmitted to the component mounter 14. Also,
When a missing item is replenished, it is possible to output which product lacks a part. Instead of automatically generating the NC data in which the missing parts are deleted, the NC data may be automatically changed so as to switch another channel in which the same parts as the missing parts are set. In any case, the contents of the NC data memory 409 as the master are not changed. As a result, even if the component mounter runs out of stock, the error information is not notified to the cell controller 2 each time, and the component mounting process is smoothly performed.

FIG. 57 shows a control flowchart of a part of the out-of-stock process or a channel change process in the cell controller 2. First, in step 551, the initial value of the channel management table 491 is preset from the NC data memory 409 via the line control system 3, and then in step 552, the initial value of the parts specification management table 490 is also set from the NC data memory 409. set. Next, at step 553, after receiving an insertion completion report signal (a signal indicating the completion of the insertion of the component into the printed wiring board) from the component mounter 14, at step 554, the work for all the printed wiring boards is completed. Determine if it is finished. When there is an unprocessed printed wiring board remaining, the process proceeds to step 555, it is determined whether or not the number of parts stored in the part specification management table 490 is in the channel in use, and the channel in use is selected. If there is a part, proceed to step 556 and create NC data. If there are not enough parts in the channel being used, the flow proceeds to step 561 and it is determined whether other channels have the same type of parts. Step 56 if other channels have same type parts
Proceed to 2 and create NC data with these two channel parts. If there is no part of the same type in another channel, the process proceeds to step 563, and NC data is created by deleting the data that uses the part in which the shortage occurred from the current NC data.

If NC data is created in step 556, 562, or 563, the process proceeds to step 557, and it is determined whether the created data is the same as the previous NC data. If they are not the same, it is necessary to send new NC data to the mounter 14, so in step 558 the NC data is sent, and in step 559 the NC data previous transmission channel table 493 is updated. If the NC data is updated in step 559 or if it is determined in step 557 that it is the same as the previous NC data, the process proceeds to step 560, and the number of parts stored in the channel management table 491. Is negatively updated and the process returns to step 553, and this routine is repeated until it is determined in step 554 that the work is completed.

FIG. 58 shows an example of changes over time in the stored contents of the tables 490-493. 6 to 9 show the stored contents of each table for each printed wiring board when processing is performed on five printed wiring boards.

First, comparing the quantity of parts in the parts specification management table 490 with the quantity of parts in the channel management table 491, the quantity of parts in the channel management table 491 for all parts is greater than or equal to the quantity in the parts specification management table 490. In this case, NC data can be created with this channel. Since there is no data in the NC data previously transmitted channel table 493, NC in the component mounter 14
Send data.

Then, the number of parts in the channel management table 491 is subtracted and updated by the number of parts for one printed wiring board, and the NC data previous transmission channel table 493 is displayed.
The NC data in is stored in. Then, since the NC data management table 492 and the NC data previous transmission channel table 493 have the same NC data, it is not necessary to transmit the NC data.

Subsequently, when processing the third printed wiring board, the number of parts 3 in the currently used channel 1 of the part b in the channel management table 491 is the part specification management table 49.
Since the number of parts is 0, which is less than 4, the shortage is allocated from unused channels 3 when creating NC data. In this case, since the channel organization of the NC data created in the NC data management table 492 is different from this, this NC data is retransmitted, and the busy flag of the channel 3 of the part b of the channel management table 491 is being used. Update to a certain “1”.

Furthermore, although it can be executed with the in-use channel organization shown in the channel management table 491, since it is different from the NC data in, it is necessary to retransmit the NC data. According to this procedure, the fifth printed wiring board is processed.

As described above, according to the above embodiment of the present invention,
The same component can now be set in multiple channels, and by automatically switching channels while checking the usage status of components, the number of component cuts can be reduced and the number of system setup steps can be reduced. It has the effect that

When setup change is required, a function that indicates the channel that needs to be changed (see Fig. 59). This function checks the setup of the product to be input next according to a predetermined input schedule.
It also manages the parts shelves where each part is stored (what is stored where). If there is a channel that requires a setup change, the operator is informed which part and which channel should be set by turning on the lamp on the part setting section of the corresponding channel and the corresponding shelf of the parts shelf.

FIG. 59 is a system configuration diagram for realizing this function. In the figure, 591 is a parts setting unit of equipment, 592 is a parts shelf, 593 is a table showing the parts specifications set for this channel, 594 is a table showing the parts specifications set for the next channel, and 595 is A table indicating the position of the shelf in which the parts are stored, 596 is a comparison unit, and 597 is a shelf address setting unit. When the next channel setting is different from the current channel setting (current channel setting) in, for example, the second, fourth, and sixth channels, the comparison unit 596 detects this and responds to the equipment component setting unit 591. In addition to turning on the lamp of the channel, the shelf address setting unit 597 sends a signal from the channel setting table to the parts setting unit 591 and the parts so as to turn on the lamp of the parts shelf 592 where the parts having the different parts specifications are stored. Send to shelf 592.

When NC data is corrected in one of the equipment with the same specifications, it is immediately reflected in other equipment (see Fig. 60). In this function, information common to the equipment with the same specifications (eg, on-board data) is stored in the cell. The cell controller is provided in the database on the line control system by referring to the database on the line control system side by using the function of the server etc. The modifications can be reflected in the cell controls of all identical equipment.

FIG. 60 is a system configuration diagram for realizing this function. In the figure, facilities 1-1 to 1-3 have the same specifications and use common information.
(N-1) and 1-N are other same-use equipment.
Conventionally, even these common information is held in each cell controller 2-1 to 2-N, and data is exchanged only between the cell controller and the corresponding equipment. In this conventional method, if the common information is modified in one cell controller,
It is complicated because it is necessary to make the same correction in other cell controllers. In this embodiment of the present invention, in order to avoid the complication, the common information is provided in the database (NC data) in the line control system 3. As a result, the correction made in the database in the line control system 3 is reflected in all the cell controllers connected to the equipment of the same specification, and the correction for each cell controller becomes unnecessary.

Function to suspend work in the middle of a lot and to restart from the next state after the system is finished (see Fig. 61) This function allows the progress status of each product at each facility to be monitored via the cell controller. All are managed by the line control system, the progress status (current work-in-progress status, etc.) is saved in a file in the power-off process, and the file is restored again in the power-on process, so that manufacturing can be resumed from the continuation that was interrupted last time. It can be started and can be interrupted at any time.

FIG. 61 is a system configuration diagram for realizing this function. In the figure, 611 is a file memory for updating and accumulating the equipment, the product name, the number of completed printed boards and the loader status in real time, and 612 is a dump file memory.

Each of the cell controllers 2-1 to 2-N refers to the file memory 611 in the line control system 3,
The facilities 1 to 1-N are controlled to perform the component mounting process.
Then, the progress status of each product in each facility is monitored by the line control system 3 via the corresponding cell controller.
Write to the internal file memory 611.

When the power is turned off, the progress status of the products in the file memory 611 is dumped in the dump file memory 612.

When turning on the power again, dump file memory 61
The contents of 2 are restored in the file memory 611.

Since the progress of the product is dumped, even if the production is interrupted, the production can be restarted from the interrupted situation.

A function to monitor the manufacturing status of the entire line with the line control system and all cell controllers (see Fig. 61). As shown in Fig. 61, the state of each facility is centrally managed by the line control system via the cell controller. As a result, not only from the line control system but also from each cell controller, it is possible to monitor the manufacturing status of the entire line, the occurrence of errors, the necessity of setup change, and the like. From this, one person can grasp the state of the entire line and take countermeasures, so that unmanned lines can be promoted. For example, when the product does not flow smoothly to one facility as planned, the cause of the delay can be confirmed by grasping the manufacturing status of the other facility from the cell controller connected to that facility. You can take measures against delays.

Function to instantly know the location and progress of the product in the line (see Fig. 62) In the past, only process completion information was known, but according to the present embodiment, the current location for each lot, which is a unit of manufacturing and transportation, can be obtained. By collectively managing the progress of other points with the line control system, it is possible to immediately know where the specified product is currently and how far the manufacturing has progressed.

FIG. 62 is a system configuration diagram for realizing this function. In the figure, the line control system 3 is provided with a real-time table 623, and the contents of the table 623 are updated in real time with the actual data from the cell controllers 2-1 to 2-N. The contents of the table 623 are displayed on the graphic screen 624 in real time.
In the line control system 3, by designating a product name, it is possible to know in real time which facility the product currently exists in, what number of lots are being manufactured, and the progress status of which item in the total quantity. be able to.

According to still another embodiment of the present invention, from the contents of the real time table 623 shown in FIG. 62, the rack start,
Extract the product name corresponding to the point of change of events such as printed board start, error occurrence, etc., and write it in the logging file 413 (see FIG. 4C) as shown in FIG. 63, for example, for one day or one week. Save it. Then, later, by reproducing the contents of the logging file on the monitor 415 in real time or in 1/10 of the real time, the situation of the past manufacturing process can be grasped in the line control system 3. As a result, it is possible to visually grasp the problem in the line such as the accumulation condition of the product in the rack and the cause thereof. The contents of the logging file 413 may be totaled and the analysis result may be displayed on the monitor 415.

[3] Function to analyze manufacturing results The following functions are provided to support the causes that hinder the improvement of operating rates and the pursuit of know-how to make a more efficient manufacturing line (Fig. 63). reference).

Function to save and reproduce manufacturing results As described above with reference to Fig. 63, the occurrence of operations (for example, rack entry / exit and printed board entry / exit) in all equipment,
By recording the occurrence / recovery of errors in the line control system in the order of occurrence time, the work can be reproduced later on the simulation program according to the actual results. As a result, the problems existing in the manufacturing line can be observed objectively.

Function to save and analyze manufacturing results By collecting the collected results, in addition to the operating rate and setup rate, the time taken from error occurrence to recovery, the frequency of occurrence for each error, and by comparing with the schedule The cause of handheld occurrence is determined and shown in the graph.

[Industrial applications]

As is apparent from the above description, the following effects are obtained by the present invention, and the applicability of the unit such as a printed board to an assembly line is extremely high.

・ By weekly schedule, it is possible to take proactive measures before the line is put into operation, and to provide an execution schedule that takes into account the status of work in progress and mechanical failure of express goods, so that it is possible to perform efficient production without confusing the line against sudden factors. .

・ Always monitor the difference between planned and actual results,
By giving appropriate work instructions to the line manager, the line operation according to the plan can be realized.

-The operating status of the entire line can be monitored at one place, and unmanned lines can be promoted.

・ The factor that hinders production can be analyzed in detail, which is useful for line improvement.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (31) Priority claim number Japanese Patent Application No. 2-18055 (32) Priority date Hei 2 (1990) January 30 (33) Country of priority claim Japan (JP) (56) References JP-A-1-183346 (JP, A) JP-A-58-154012 (JP, A) JP-A-58-129608 (JP, A) JP-A-63-93550 (JP, A) JP-A-61-226252 (JP, A)

Claims (15)

(57) [Claims] 1. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In the manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the executed schedule, the line control system detects the actual occurrence detected by the cell controller. A means (412) for analyzing an alarm from the equipment, which is one of the events, and a recovery failure as a result of the analysis of the alarm. When capacity or time to recovery is determined to be such, said equipment is not automatically performed rescheduling as to recreate the execution schedule,
A manufacturing control system comprising a means (34) for displaying a message prompting rescheduling when the cause of the failure is unknown even after the alarm is analyzed. 2. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In a manufacturing control system that controls the equipment, the cell controller, the component mounter, and the transfer means based on the performed execution schedule, a predetermined time is required for setup for changing processing conditions between the steps. The line control system obtains the total work time of the products input in each process when A priority table (155) for ranking and storing the plurality of processes, a sort table (158) for grouping and storing the products for each processing condition of the processes in the order of processes according to the ranking, and Means (143) for arranging the groups of products or products grouped in the sort table so that the processing conditions for adjacent groups of products or products match as much as possible, and set up in descending order of total working time. A manufacturing control system characterized in that the execution schedule is created so as to determine the order of introduction by grouping so as to minimize the number of times. 3. The manufacturing according to claim 2, wherein there is a request for handling an express item as one of the actual occurrence events, and when the request for handling an express item is made, the express item is input with the highest priority. Control system. 4. As one of the actual occurrence events, there is a demand for handling express goods, and when there is a demand for handling express goods, the margin for the delivery date of the express goods is shorter than the margin for the delivery date of normal products. The manufacturing control system according to claim 2, wherein the execution schedule is created. 5. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In the manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the performed execution schedule, a free time management table (212) for managing free time for each process , A process history table (211) that retains the history of jobs processed in that process, and the number of man-hours required to take the moving time between processes into consideration Table (215), the job to be input has a process path and man-hours in each process, and the input time, end time, and discharge time to the next process according to the process path for each job A manufacturing control system, wherein the execution schedule is created by recursively simulating. 6. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In the manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the executed schedule, the line control system includes the execution schedule and the results from the component mounter. Schedule performance comparison means (422) for constantly comparing and and means for detecting a difference due to the comparison and issuing a warning. The line control system comprises means (412) for analyzing an alarm from the equipment, which is one of the actual occurrence events detected by the cell controller, and an unrecoverable result as a result of the analysis of the alarm. When it is determined that the restoration will take time, it is automatically determined that the equipment is not present and the execution schedule is recreated,
The manufacturing control system further comprising means (34) for displaying a message prompting rescheduling when the cause of the failure is unknown even after analyzing the alarm. 7. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In a manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the executed execution schedule, each of the equipments detects the presence or absence of a product at a product inlet. The line control system includes a product detection unit (41), and the line control system manages a work schedule of each of the facilities (a schedule management table ( 41A) and a process route management table (42A) for managing the process route and the current location for each product, and the line control system detects that the product detection unit has an empty inlet of the equipment. The process route management table is referred to, which facility the product to be carried into the facility next, which is indicated by the schedule management table, is currently checked, and the transport means is instructed to transport the product. Manufacturing control system. 8. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In a manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the executed execution schedule, each of the equipments detects the presence or absence of a product at a product inlet. A product that is equipped with a product detection unit (41) and should be received next when the product detection unit detects that there is no product at the inlet of the plurality of facilities. Transport request generation means (4
2) is provided, the presence or absence of a product at the input port of the plurality of facilities is confirmed by the product detection unit, and when there is no product at the input port, the transfer request generation unit requests the transfer of the next product, The line control system collates the content of the transportation request generated by the transportation request generation means with the processed product, and when there is a product with a collated result, the transportation means instructs the transportation means to transport the product. A production control system characterized by issuing 9. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In the manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the performed execution schedule, the component mounter detects unmounted component detection Means for controlling the component mounter based on the information on the missing component from the unmounted component detecting means when a component is out of stock during processing of the product. The cell controller is provided with means for notifying the line control system of the out-of-stock information, and the line control system stores the out-of-stock part name based on the out-of-stock information. A manufacturing control system comprising a product management memory. 10. The cell controller receives, from the line control system, means for receiving NC data indicating a relationship between a component and a position of a channel in the component mounter in which the component is mounted, and the out-of-stock information. 10. The manufacturing according to claim 9, further comprising means for automatically generating new NC data in which the NC data is updated to delete the missing parts and means for retransmitting the new NC data to the component mounter. Control system. 11. The cell controller receives, from the line control system, means for receiving NC data indicating a relationship between a component and a channel position in the component mounter in which the component is mounted, and the out-of-stock information. A means for automatically generating new NC data in which the NC data is updated to associate the missing part with another channel in which the same part as the missing part is accommodated, and the new NC data for the component mounter. 10. The manufacturing control system according to claim 9, further comprising: 12. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In the manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the performed execution schedule, the equipment includes a component shelf (592) in which components are stored, A parts setting section (591) for taking out the parts from the parts shelf and setting the parts in the product, and the parts shelf stores the accommodating position for each part as necessary. The part setting unit includes a part for displaying a relationship with a part set for each channel in which a product is accommodated, if necessary, and the line control system includes any one of the facilities. When there is a need to change the relationship between the component to be put in and the channel, it is provided with means for displaying the position of the component requiring the change in the component shelf and the position of the channel in the component setting unit. Manufacturing control system. 13. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In the manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the performed execution schedule, the line control system includes an NC for a component to be mounted for each of the equipment. An NC data memory (409) for storing data is provided, and at least two of the equipment have the same specifications and the same NC data. It is intended to be controlled by the motor,
The production control system, wherein the line control system is provided with means for, when NC data relating to one of the equipment having the same specification is modified, immediately reflecting the modification to another equipment having the same specification. 14. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In the manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the performed execution schedule, the line control system interrupts work in the middle of a lot, and system operation is performed. Equipped with a dump file memory (612) that dumps the state at the time of work interruption when
After the system is restarted, the manufacturing control system is characterized in that the work can be restarted from the state held in the dump file memory. 15. A plurality of facilities (1) including a component mounter (14) for processing a plurality of products through a plurality of processes.
And a plurality of cell controllers (2) for controlling the equipment
And a line control system (3) for centrally controlling all of the cell controllers, and a transfer means (4) for transferring between the facilities under the control of the line control system. Created by means (401) that creates a detailed execution schedule that takes into account the relatively short-term plan cut out from the relatively long-term schedule, the in-process status of the product and the actual occurrence event in real time In the manufacturing control system configured to control the equipment, the cell controller, the component mounter, and the transfer means based on the executed execution schedule, the line control system controls the state of each of the equipment by the cell controller. The manufacturing control system is characterized by having means for collecting the information via all the devices and notifying each cell controller of the status of all equipment. Temu.