JP4398119B2 - Parts replacement monitoring method and system - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a material replacement monitoring method and system, and more specifically, prevents an error in replacement material at the time of material replenishment in a production facility, or an error in replacement parts at the time of component replenishment in an electronic component mounting facility, The present invention relates to a monitoring method and a monitoring system for manufacturing a high-quality product.
[0002]
[Prior art]
As is well known, in general production equipment and mounting equipment, there is no space to secure all materials or parts together, so that the materials or parts are replenished every time they are used up. Yes.
In particular, most electronic components mounted on a printed circuit board or the like are supplied to mounting equipment in a form in which a predetermined number of bands are wound on a reel. Therefore, parts that have used up a predetermined number in the mounting process are replenished by exchanging the reels.
[0003]
FIG. 8 is a schematic view showing a part related to component supply of a conventional mounting facility for mounting electronic components on a printed circuit board or the like. Hereinafter, a component replacement method performed in a conventional mounting facility will be described with reference to FIG.
When a component breakage occurs in the mounting facility, an empty reel (hereinafter referred to as an empty reel) loaded at the component supply position 104 on the component supply table 103 and a new reel filled with the component. By replacing (hereinafter referred to as a supply reel), parts are supplied. Usually, the mounting equipment displays on the screen (not shown) the supply position or product number of the parts to be replenished and stops the operation when the parts are out of stock. After confirming the supply position and part number of the parts to be replenished on the screen, the operator replaces the empty reel with a replenishment reel of the same part number and restarts the operation of the mounting equipment.
[0004]
However, since this reel replacement is performed manually by an operator, in a mounting facility that uses a plurality of parts, a supply reel with an incorrect product number is replaced or a supply reel is replaced at an incorrect supply position. There is a fear. Therefore, conventionally, in a mounting facility that uses a plurality of components, in order to prevent these mistakes, an identifier such as a bar code that can uniquely identify the components that are filled in the reel is attached in advance to replace the empty space. The barcode of the reel and the barcode of the supply reel are mutually confirmed using a portable terminal or the like having a barcode reading function (two-point verification). Or, use a barcode form in which the supply position and part number of the components mounted on the board are printed as barcodes, and mutually confirm the barcode of the form, the barcode of the empty reel, and the barcode of the supply reel. (3-point verification).
[0005]
For example, in the three-point collation shown in FIG. 8, a reel (empty reel 107 and supply reel 108) to which a label of barcode 109 is attached in advance and a barcode form 102 are used. Further, in the memory of the mobile terminal 1 that can read the barcode, data for associating the supply position of the component mounted on the board with the barcode of the product number is stored in advance.
First, when the mounting equipment is stopped, the operator inputs the supply position number of the component to be replenished displayed on the screen to the portable terminal 1 or uses the barcode form 102 to set the supply position number of the component. The barcode of the corresponding product number is read and input to the portable terminal 1. Next, the operator reads the barcode 109 attached to the empty reel 107. When the two barcodes are read, the portable terminal 1 compares (collates) these barcodes (the barcode of the part to be supplied and the barcode 109 of the empty reel 107). Here, if the two bar codes are different (bar code error), the fact that the bar code has been collated is displayed on the portable terminal 1 and the operator is prompted to read the correct empty reel bar code again. . On the other hand, if the two barcodes match, the operator subsequently reads the barcode 109 of the supply reel 108. In the mobile terminal 1, the barcode 109 of the supply reel 108 is compared with the two barcodes. If the three bar codes are different, a message indicating that the bar code has been collated is displayed on the portable terminal 1, and the operator is prompted to read the correct bar code on the supply reel again. The collation result is read from the portable terminal 1 as history data together with the work time, and can be managed by an external storage unit (not shown).
Such a three-point verification prevents a supply reel error and a supply location error when replacing parts.
[0006]
Note that a two-point collation method that collates only the barcode of the empty reel and the barcode of the supply reel without using the bar code form is simpler than the above three-point collation method. However, this two-point verification method has a problem that even if a reel adjacent to a reel to be exchanged is mistakenly exchanged, it is determined that the system is correct.
[0007]
[Problems to be solved by the invention]
However, the conventional three-point matching described above causes the following problems.
First, if the barcode of the parts to be replenished is correctly matched with the barcode of the empty reel, and an error occurs many times in the verification of the barcode of the supply reel, the operator mistakenly Even if the code is read again, the system determines that the verification is correct.
Secondly, when there is almost no remaining part of the reel adjacent to the reel where the part breakage has occurred, the operator may replace the two reels at the same time. In this case, even if the operator mistakenly loads the two supply reels in the opposite positions, the system determines that the supply is correct.
As described above, in the conventional component replacement method, there is a possibility that the wrong component reel is loaded by the operator.
[0008]
Therefore, the object of the present invention is to maintain and analyze the history of the material or part replacement (supply) procedure, and to output a phenomenon that may be erroneous even if the wrong material or part is replaced or It is an object to provide a material exchange monitoring method and system that enables production of a high-quality product by displaying.
[0009]
[Means for Solving the Problems and Effects of the Invention]
A first invention is a component replacement monitoring method for preventing wrong parts from being supplied at the time of artificial part replacement performed in a mounting facility for mounting a plurality of electronic components on a printed circuit board.
For each part replacement operation procedure, a step of collating part-specific information with a replacement part and a replacement part;
In the collation operation between the replacement part and the replacement part performed in the collating step, the operation procedure in which the parts-specific information of both parts did not match and the collation information indicating the generation time of the operation procedure are stored in the history database. Accumulating steps;
Using the collation information stored in the history database, search for operation procedures that occurred between the current time and a predetermined time in the past, and register in the rule database the number of times that component-specific information mismatches have been repeated continuously Extracting an operation procedure that exceeds a reference number for determining a suspected component replacement mistake,
A step of displaying, on the output device, a warning indicating that there is a suspicion of a component replacement error for the operation procedure extracted in the extracting step .
[0018]
As described above, according to the first invention, when a component verification error occurs due to an error in the operation procedure performed by the operator, a result of a suspected component verification error based on the predetermined rule information is obtained. Display on sequential output device. Thereby, quality loss can be reduced and a high quality product can be manufactured.
[0020]
A second invention is a component replacement monitoring system used for mounting equipment for mounting a plurality of electronic components on a printed circuit board to prevent supply of an erroneous component during artificial component replacement,
For each operating procedure part replacement, the component specific information against by the replacement part and the replacement part, the matching work of the replacement part and the replacement part, the operation part specific information both parts do not match the procedure And a portable terminal capable of holding and transmitting collation information indicating the occurrence time of the operation procedure ;
An input processing unit that receives collation information transmitted from the mobile terminal;
A history database in which collation information received by the input processing unit is accumulated;
A rule database in which the standard number of times to determine the suspicion of parts replacement is registered,
Using the collation information stored in the history database, the operation procedure that occurred between the current time and the past predetermined time was searched, and the number of times that the mismatch of the parts-specific information was repeated continuously was stored in the rule database A search processing unit for extracting operation procedures exceeding the reference number of times ;
The operation procedure extracted by the search processing unit is provided with a display output unit that outputs a warning indicating that there is a suspicion of component replacement error to a display or an external signal and outputs it to the mounting equipment.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a case where the material replacement monitoring method provided by the present invention is applied to a mounting facility for mounting electronic components on a printed board or the like will be described as an example.
FIG. 1 is a block diagram showing a configuration of a material exchange monitoring system according to an embodiment of the present invention. In FIG. 1, the material exchange monitoring system according to the present embodiment includes a portable terminal 1, a repeater 2, an input processing unit 3, a history database 4, a rule database 5, a search processing unit 6, and a display output unit. 7.
First, the outline | summary of each structure of the material replacement | exchange monitoring system which concerns on this embodiment is demonstrated.
[0022]
The portable terminal 1 has a barcode reading function that can read a barcode label attached to a reel of parts, and can input numbers from a numeric keypad. In addition, the portable terminal 1 performs a collation operation of the read barcode to hold all or a part of the collation information, and transmits the collation information wirelessly or by wire as necessary. The repeater 2 relays the collation information transmitted from the mobile terminal 1 to the input processing unit 3. The general repeater 2 receives verification information transmitted from a plurality of portable terminals 1 as a wireless signal or a wired signal, and transmits it to the input processing unit 3 via a network. The verification information may be transmitted directly from the portable terminal 1 to the input processing unit 3 through a dedicated line without using the repeater 2. The input processing unit 3 processes the collation information transmitted via the repeater 2 and stores and manages it in the history database 4. The rule database 5 holds and manages rule information that induces component replacement mistakes in advance. The search processing unit 6 searches whether the content corresponding to the rule information managed in the rule database 5 exists in the collation information managed in the history database 4. Then, the search processing unit 6 outputs the search result to the display output unit 7. The display output unit 7 displays the search result given from the search processing unit 6 on the screen.
[0023]
Next, specific processing of each component of the material replacement monitoring system according to the present embodiment will be described with reference to FIGS. FIG. 2 is a flowchart showing the procedure of the barcode matching process performed by the mobile terminal 1. FIG. 3 is a diagram illustrating an example of the data structure of the history database 4. FIG. 4 is a diagram illustrating an example of the data structure of the rule database 5. FIG. 5 is a flowchart showing a procedure of collation information search processing performed by the search processing unit 6. FIG. 6 is a diagram illustrating an example of a search result screen displayed on the display output unit 7.
[0024]
Initially, with reference to FIG. 2, the barcode collation process which the portable terminal 1 performs is demonstrated. When a component breakage occurs in the mounting facility and the supply position of the component is displayed on the screen, the operator inputs the supply position of the component (component to be supplied) from the numeric keypad to the portable terminal 1 (step S201). ). The portable terminal 1 checks whether or not the input supply position is a supply position (effective supply position) defined by the mounting equipment (step S202). Here, if the input supply position is not the effective supply position, the mobile terminal 1 determines that the supply position of the component has been input incorrectly, and stores the state of “supply position error” along with the date and time when the error occurred ( Step S203).
[0025]
On the other hand, when the portable terminal 1 confirms that the input supply position is an effective supply position, the operator reads the barcode of the empty reel (step S204). The mobile terminal 1 acquires the barcode of the part corresponding to the input supply position based on the data for associating the supply position of the part and the barcode of the part number held in advance. It is checked whether the bar code matches (step S205). Here, when both barcodes do not match, the mobile terminal 1 determines that the barcode of the wrong part has been input, that is, the empty reel to be replaced is wrong, along with the date and time when the mistake occurred, The state of “(1)” is stored (step S206). Further, the portable terminal 1 stores attribute information such as the part number of the wrong empty reel as necessary (step S206). Thereafter, the mobile terminal 1 further determines whether or not the “reading error (1)” state has reached a predetermined number of times (step S207). If not, the operator again reads the barcode of the correct empty reel. (Step S204). Note that step S207 is performed in order to forcibly end the process before the action has a great influence on manufacturing when repeated input is made repeatedly, and is a predetermined criterion as a judgment criterion. The number of times can be set freely in consideration of the influence of the action.
[0026]
When the portable terminal 1 confirms that both barcodes match in step S205, the worker next reads the barcode on the supply reel (step S208). Then, the mobile terminal 1 collates whether the empty reel barcode and the supply reel barcode match (step S209). Here, when both barcodes do not match, the mobile terminal 1 determines that the barcode of the wrong part has been input, that is, the supply reel to be replaced is wrong, The state (2) "is stored (step S210). Further, the portable terminal 1 stores attribute information such as the part number of the wrong supply reel as necessary (step S210). Thereafter, the mobile terminal 1 further determines whether or not the “reading error (2)” state has reached a predetermined number of times (step S211), and if not, the operator reads the correct supply reel barcode again. (Step S208). Note that the determination in step S211 is performed for the same reason as in step S207.
If it is confirmed in step S209 that both barcodes match, the mobile terminal 1 determines that normal parts replacement has been performed, and stores a state of “normal end” along with the date and time (step S212).
[0027]
The mobile terminal 1 then completes the replacement of parts normally (step S212), if the supply position of the parts is entered incorrectly (step S203), or if the reading error of the empty reel continues a predetermined number of times (step S207). , Yes), and when the supply reel reading error continues a predetermined number of times (step S211, Yes), all the states and date / time stored so far are input as matching information together with the route number of the last processing. The data is transmitted to the processing unit 3 (step S213).
When the barcode verification process is completed on the mobile terminal 1, the input processing unit 3 registers the verification information transmitted from the mobile terminal 1 in the history database 4.
[0028]
Depending on the mounting equipment, a reel of parts is filled in a predetermined cassette (or tray) and installed at the part supply position. In such a mounting facility, a specific part may not be filled in the same predetermined cassette due to replacement of the cassette or the like. Therefore, as a countermeasure for such a case, a barcode label assigned with a unique cassette ID may be attached to each cassette in advance, and the barcode verification of the cassette may be further performed after the barcode verification of the supply reel. The bar code collation status of the cassette may be registered in the history database 4 as collation information.
[0029]
Next, the data structure of the history database 4 will be described with reference to FIG.
In the history database 4, items of operation number 31, component supply position 32, route number 33, occurrence date and time 34, state 35 and attribute 36 are managed based on the collation information transmitted from the mobile terminal 1. The operation number 31 stores a serial number assigned in units of collation information (a series of work performed for a certain part cut) transmitted from the mobile terminal 1, and is used for information management of the worker. Accordingly, when a plurality of work mistakes occur in a work for a part cut, there are a plurality of the same operation numbers (“1” in the example of FIG. 3). The component supply position 32 stores the number of the supply position of the mounting equipment that the operator has targeted for component replacement. As described with reference to FIG. 2, the route number 33 stores the route number of the final process that has led to step S213. The occurrence date and time 34 stores the date and time when the component replacement error occurred or the date and time when the component replacement was normally performed. The state 35 stores a state (part replacement error or normal end) that occurred on the date and time indicated by the occurrence date and time 34. The attribute 36 stores necessary attribute information such as a part number that has been misread.
[0030]
Next, the data structure of the rule database 5 will be described with reference to FIG.
In the rule database 5, items of rule number 41, application 42, condition 43, condition attribute 44, and occurrence display 45 are managed in advance as rule information. The rule number 41 stores an identification number that identifies a predetermined rule. The application 42 stores an instruction as to whether or not the rule is applied to search for collation information. The condition 43 stores a rule condition determined in the search for collation information. The condition attribute 44 stores predetermined attribute information (threshold value or the like) that serves as a criterion for determining rule conditions. The occurrence display 45 stores contents to be displayed on the screen of the display output unit 7 when the existence of the corresponding rule is confirmed by the search of the collation information.
[0031]
In the example shown in FIG. 4, the following rule information is managed. Rule number 1 defines a rule regarding how many times the “reading error (1)” state is repeated continuously, and if it is repeated three or more times, a warning “an empty reel error has occurred” is issued. Is set. Rule number 2 defines a rule regarding how many times the state of “reading error (2)” has been repeated consecutively, and if it is repeated three or more times, a warning “a supply reel error has occurred” is issued. Is set. Further, a rule regarding whether or not “simultaneous replacement of two reels” is performed as rule number 3 is defined, and the replacement time T1 of one reel and the replacement time T2 of the other reel are | T1-T2 | <60 seconds. If it is within the range, it is set to give a warning that “simultaneous exchange of materials has occurred”. Further, as a rule corresponding to the case where the above-described cassette is used, rule No. 4 defines a rule relating to “relation between cassette and filling part”, and the cassette ID and the replaced part number are different from the previous relation. In such a case, a warning that “the product number is inconsistent with the cassette ID” is issued. Furthermore, a rule regarding “parts out” is defined as rule number 5 and there is a remaining number of parts (which can be obtained by subtracting the number of parts used in the equipment from the initial number at the time of part replacement). It is set to issue a warning that “there are still parts left”.
Note that these rules are merely examples, and various other rules can be freely defined.
[0032]
Next, referring to FIG. 5 further, the collation information search process based on the rule information performed by the search processing unit 6 will be described. This search process is automatically performed periodically.
First, the search processing unit 6 specifies a search range of collation information managed in the history database 4 (step S501). This search range is normally specified retroactively from the latest data on the occurrence date 34. However, it is assumed that the search range can be selected and specified by the operator as necessary. In FIG. 5, for the sake of simplicity, the search range is represented by the operation number 31 (N to N + M). Next, the search processing unit 6 determines whether or not the rule information in the rule database 5 corresponds to the collation information of the operation number N that is the first in the search range (steps S502 and S503). Here, the search processing unit 6 applies only the rule whose “application” item is “Yes” in the rule database 5. When the search processing unit 6 confirms the presence of the rule corresponding to the collation information of the operation number N as a result of the search, the search processing unit 6 outputs the rule generation display 45 to the display output unit 7 (step S504).
The search processing in steps S503 and S504 is performed for all collation information (operation numbers N to N + M) in the specified search range (steps S505 and S506).
[0033]
Finally, with reference to FIG. 6 further, an example in which the corresponding rule information searched by the search processing unit 6 is displayed on the screen of the display output unit 7 will be described.
Information displayed on the screen includes an operation number 61, a component supply position 62, an occurrence date and time 63, an occurrence display 64 registered in the rule database 5, its attribute 65, a confirmation registration 66 for confirming a collation error by an operator, and an empty reel. It consists of the items of item number 67, supply reel item number 68 and worker 69. Normally, this information is displayed in order from the latest occurrence date and time. In the present embodiment, past information that cannot be displayed on the screen can be referred to by operating the scroll bar 70. Further, by operating the detail button 71, the detailed contents of the selected information, for example, the contents of the history database 4 shown in FIG. 3 can be confirmed. The display range is linked to the search range described above and is updated periodically. Furthermore, the search range can be entered in the input field 72.
[0034]
As described above, according to the material replacement monitoring method and system according to an embodiment of the present invention, when a component (material) verification error occurs in the mobile terminal 1 due to an error in the operation procedure performed by the operator. Sequentially displays the result with the possibility (suspicion) of component matching error on the display output unit 7 based on the predetermined rule information. Thereby, quality loss can be reduced and a high quality product can be manufactured.
[0035]
In the above embodiment, the case where the search result output from the search processing unit 6 is displayed on the screen of the display output unit 7 has been described. However, in addition to this, as shown in FIG. 7, there is further provided a signal output unit 10 that converts the search result output from the search processing unit 6 into a signal format corresponding to the external mounting equipment 11 and outputs the signal. Search results may be displayed on the screen on the equipment 11 side, or the mounting equipment 11 may be directly controlled (operation stopped, etc.).
[Brief description of the drawings]
FIG. 1 is a block diagram showing a configuration of a material exchange monitoring system according to an embodiment of the present invention.
FIG. 2 is a flowchart showing a procedure of barcode collation processing performed by the mobile terminal 1;
FIG. 3 is a diagram illustrating an example of a data structure of a history database 4;
FIG. 4 is a diagram illustrating an example of a data structure of a rule database 5;
FIG. 5 is a flowchart showing a procedure of collation information search processing performed by the search processing unit 6;
6 is a diagram showing an example of a search result screen displayed on the display output unit 7. FIG.
FIG. 7 is a block diagram showing another configuration of the material exchange monitoring system according to the embodiment of the present invention.
FIG. 8 is a diagram showing an example of a method for component verification in a conventional mounting process.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Portable terminal 2 ... Repeater 3 ... Input processing part 4 ... History database 5 ... Rule database 6 ... Search processing part 7 ... Display output part 8 ... Component reel 9, 109 ... Barcode 10 ... Signal output part 11 ... Mounting equipment 102 ... Bar code form 103 ... Part supply table 104 ... Part supply position 107, 108 ... Reel

Claims (2)

A component replacement monitoring method for preventing wrong parts from being supplied at the time of artificial part replacement performed in a mounting facility for mounting a plurality of electronic components on a printed circuit board.
For each part replacement operation procedure, a step of collating part-specific information with a replacement part and a replacement part;
In the collation operation between the replacement part and the replacement part performed in the collation step, collation information indicating the operation procedure in which the parts-specific information of both parts do not match and the occurrence time of the operation procedure is stored in the history database. The steps to accumulate in
The collation information stored in the history database is used to search for operation procedures that have occurred from the current time to a predetermined time in the past, and the number of times that the inconsistency of information unique to the component is continuously repeated is stored in the rule database in advance. A step of extracting an operation procedure exceeding a reference number for judging a suspicion of a registered part replacement error;
A component replacement monitoring method comprising: displaying, on an output device, a warning indicating that there is a suspicion of a component replacement error for the operation procedure extracted in the extracting step. Used in mounting equipment for mounting a plurality of electronic components on a printed board, a component replacement monitoring system for preventing the supply of the wrong parts artificial parts when replacing,
For each operating procedure part replacement, the component specific information against by the replacement part and the replacement part, the matching work of the replacement part and the replacement part, the operation part specific information both parts do not match the procedure And a portable terminal capable of holding and transmitting collation information indicating the time of occurrence of the operation procedure ;
An input processing unit that receives the verification information transmitted from the mobile terminal;
A history database in which the collation information received by the input processing unit is stored;
A rule database in which the standard number of times to determine the suspicion of parts replacement is registered,
The collation information stored in the history database is used to search for an operation procedure that has occurred from the current time to a predetermined time in the past, and the number of times that the inconsistency of information unique to the component is continuously repeated is stored in the rule database. A search processing unit for extracting an operation procedure exceeding a specified reference number ,
For the operation procedure in which the retrieval processing unit is extracted, and a warning stating that the suspected component replacement miss, and a display output unit for outputting to the mounting equipment to convert the output or external signal by the screen display, parts Exchange monitoring system.

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