JP7061469B2 - Productivity evaluation system and its method - Google Patents

Description

The present invention relates to a productivity evaluation system and a productivity evaluation method for a manufacturing apparatus in a production line.

In general, when producing a large amount of products, a production line is often constructed by connecting a plurality of manufacturing devices necessary for production. For example, an electronic component mounting line that produces a substrate on which electronic components are mounted is constructed by connecting a component mounting machine, a solder printing machine, an adhesive coating device, a reflow device, an inspection device, and the like. In general, these manufacturing devices can acquire their own operation information, such as cycle time and downtime due to various obstructive factors. Further, in recent years, a device for collectively monitoring a plurality of manufacturing devices for constructing a production line has been used.

As an example of this type of monitoring device, the electronic component mounting system disclosed in Patent Document 1 sets the cycle time from the delivery of a printed substrate to the delivery in each manufacturing device constituting a production line in chronological order. A method has been proposed in which the shortest cycle time, the measured average cycle time, etc. are calculated for each manufacturing device by monitoring, and the bottleneck device is identified, and the problem of the manufacturing device and the permanent production loss are detected.

Japanese Unexamined Patent Publication No. 2013-115218

However, in the method for analyzing the capacity and production loss of a manufacturing apparatus based on the monitoring of cycle time as disclosed in Patent Document 1, some error occurs while the manufacturing apparatus is processing the previous product. The waiting time in the manufacturing equipment due to the stoppage and the waiting time in the manufacturing equipment due to the stoppage of the manufacturing equipment of other previous processes connected in the production line are not taken into consideration. Therefore, it is difficult to properly distinguish whether the change in the cycle time of the manufacturing apparatus is due to the change in the waiting time or the change in the operating time.

Further, in the manufacturing apparatus, there are a normal state in which processing is normally completed and an error state including a stop time due to some error, and the stop time in a minor error state is short and the frequency of occurrence is high. Therefore, it is difficult to properly distinguish whether the cycle time transition is a transition in a normal state or a transition due to a minor error.

The present invention has been made in view of such circumstances, and is a productivity evaluation system that improves the productivity of the entire production line by accurately analyzing and grasping the production state of the production equipment constituting the production line. The purpose is to provide a productivity evaluation method.

A preferred example of the productivity evaluation system of the present invention is a system for evaluating the productivity of a production line that produces a product by a series of processes by a plurality of manufacturing devices, from the manufacturing device to the manufacturing start time and manufacturing for each product. Aggregation period from the operation information storage device that collects information on the end time and error occurrence time, determines whether an error has occurred during the operation time of each product, and stores the operation information, and the operation information storage device. The normal actual operation information in which no error has occurred is extracted, and the normal actual operation information is assembled as a set for each aggregation interval, and is provided with a productivity evaluation device for calculating statistical values of actual operation time.

Further, as another feature of the present invention, in the productivity evaluation system, the productivity evaluation device extracts all operation information without errors during the aggregation period classified by the manufacturing device and the product model, and the normal results are obtained. Store as operation information.

Further, as yet another feature of the present invention, in the productivity evaluation system, the productivity evaluation device creates an average value of actual operating hours and a standard deviation for each aggregation interval in a graph of time-series transition. , Display on the display, on the terminal at the manufacturing site, or on the monitor of the control unit of each manufacturing device.

Further, a preferred example of the productivity evaluation method of the present invention is a method in which a computer evaluates the productivity of a production line that produces a product by a series of processes by a plurality of manufacturing devices, and the computer can be used from each manufacturing device. Information on the manufacturing start time, manufacturing end time, and error occurrence time for each product is collected, and the error occurrence time is matched between the manufacturing start time and the manufacturing end time of each operation information for each product to generate an error. Judging the presence or absence, accumulating operation information, extracting all operation information without errors during the aggregation period classified by manufacturing equipment and product model, storing it as normal actual operation information, and performing actual operation for each aggregation interval. The average value and standard deviation of time are created in a graph of transition over time and displayed on the display unit, the terminal at the manufacturing site, or on the monitor of the control unit of each manufacturing device.

According to the present invention, it is possible to provide a productivity evaluation system and a productivity evaluation method for improving the productivity of the entire production line by accurately analyzing and grasping the production state of the production equipment constituting the production line.

It is an example of the block diagram of the productivity evaluation system composed of the productivity evaluation apparatus and the operation information storage apparatus in Examples 1 and 2 of this invention. It is a top view of the operation area, the operation waiting area, and the carry-out waiting area inside the manufacturing apparatus. FIG. 3A includes an example of device operation log information read from a certain manufacturing device, FIG. 3B includes an example of device error log information, and FIG. 3C includes an error determination result. It is a figure which shows the example of the operation information of the manufacturing apparatus. It is a figure which shows the example of the data table stored in the manufacturing apparatus operation information storage area 173. It is a flowchart which the normal performance operation time totaling unit 112 executes. It is a figure which shows the example of the data table stored in the normal performance operation information storage area 124. It is a figure which shows the example of the data table stored in the normal actual operation time statistical result storage area 125. It is a figure which shows the example of the data table stored in the past statistical information storage area 126 in Example 2. FIG. It is a flowchart which executes the failure tendency determination threshold value setting unit 113 in Example 2. It is a figure which shows an example of the normal actual operation time statistical value transition output by the normal actual operation time statistical value report part 114.

Hereinafter, examples will be described with reference to the drawings.

FIG. 1 shows a productivity evaluation device 100 that monitors operation information and error information of each manufacturing device and calculates statistical information of normal actual operating time in order to evaluate the productivity of each manufacturing device 200 constituting the production line. , And an example of a block diagram of a productivity evaluation system composed of an operation information storage device 170.

The productivity evaluation device 100 can be configured on a general-purpose computer, and its hardware configuration includes a calculation unit 110 composed of a CPU (Central Processing Unit), a RAM (Random Access Memory), and a ROM (Read). Only Memory), HDD (Hard Disk Drive), storage unit 120 composed of SSD (Solid State Drive) using flash memory, operation unit 130 composed of input devices such as keyboard and mouse, LCD (Liquid) Crystal Display), a display device such as an organic EL display, a display unit 140 composed of various output devices, a communication unit 150 composed of an NIC (Network Interface Card), and the like.
The communication unit 150 is connected to the operation information storage device 170, the manufacturing site terminal 180, and each manufacturing device 200 constituting the production line via the network 160 of the wireless network or the wired network.

The arithmetic unit 110 realizes each of the following functional units by loading the manufacturing apparatus productivity evaluation program 121 stored in the storage unit 120 into the RAM and executing the program on the CPU. The calculation unit 110 includes a productivity evaluation condition setting unit 111, a normal actual operating time totaling unit 112, a failure tendency determination threshold setting unit 113, and a normal actual operating time statistical value reporting unit 114.

The operation information storage device 170 is a database server configured on a general-purpose computer, and the operation information collection unit 171 realized by the calculation unit periodically collects operation information and error information from each manufacturing device. The error presence / absence determination unit 172 determines the presence / absence of an error, and stores the collected data in the manufacturing apparatus operation information 173 for a certain period of time.

In FIG. 2, for example, an operating area 202 and a product 205 for manufacturing such as mounting electronic components on a product (printed circuit board) 204 inside a manufacturing apparatus 200 for mounting electronic components on a printed circuit board are carried in and operated. An overview view of the operation waiting area 201 held in the waiting state and the carry-out waiting area 203 holding the manufactured product 206 before being sent to the next process is shown.

For example, in the electronic component mounting device, the operation history information of the manufacturing device is recorded in the manufacturing device log (device operation log, device error log) in the control device in preparation for reference in maintenance or the like. For example, the information contained in the device operation log includes (1) how many products (sheets) of the product model x, the time when manufacturing starts, (2) the state and time of each part in the manufacturing device, and (3) operation. Time to move the product from the waiting area 201 to the operation area 202, (4) Time to start manufacturing (mounting, processing, etc.) in the operation area 202 for each product, (5) Operation detailed information and time for each product, (6) Time to end manufacturing (mounting, processing, etc.) in the operating area 202 for each product, (7) Move the product after manufacturing (mounting, processing, etc.) from the operating area 202 to the carry-out waiting area 203. There are times, etc.

In addition, for example, the information contained in the device error log includes error occurrence time and error identification, from minor errors such as parts outages and suction errors that recover in a few seconds to a few minutes to various errors that take a long time to recover. There are codes, component IDs in manufacturing equipment related to errors, and so on.

The operation information collection unit 171 of the operation information storage device 170 is activated once every hour every day of the operation day, for example, as a predetermined access timing, and is used as a control device for all the production devices of all the target production lines. On the other hand, each manufacturing device is sequentially accessed, and the information of the device operation log for one hour before the access and the information of the device error log are read out.

From the information in the device operation log, in this embodiment, the time when manufacturing (mounting, processing, etc.) is started in the operating area 202 and the time when manufacturing is finished are read out for each product. At the same time, the error occurrence time is read from the information in the device error log.
FIG. 3A shows an example of device operation log information including information of a manufacturing start time 301 and manufacturing end time 302 read from a certain manufacturing device, and FIG. 3B shows an example of information read from the same manufacturing device. An example of the device error log information including the information of the error occurrence time 303 is shown.

The error presence / absence determination unit 172 of the operation information storage device 170 determines at each manufacturing start time 301, which product ID in FIG. 3 (A) the error occurrence time 303 in FIG. 3 (B) occurred during manufacturing. Judgment is made by comparing with the production end time 302. In the examples of FIGS. 3A and 3B, it is determined that the error # 1 occurs during the manufacturing of the product ID = 102. (If an error occurs during manufacturing of a product, the operation of the manufacturing equipment is temporarily stopped, and there is a waiting time until it is restored. Normally, the operating time from the manufacturing start time to the manufacturing end time is long. The operation information collecting unit 171 stores the operation information (see FIG. 3C) including the determination result 304 of the presence or absence of the error in the manufacturing equipment operation information storage area 173.

FIG. 4 shows an example of a data table stored in the manufacturing equipment operation information storage area 173. The data record of each row of 401 stores a part of the operation information of each product of the manufacturing device number = 1 and the product model = 3 manufactured on September 12, and the data record of each row of 403 is 9 A part of the operation information of each product of the manufacturing device number = 1 and the product model = 3 manufactured on the 19th of March is stored. Then, in each line of 402 in the meantime, the remaining products of manufacturing device number = 1, product model = 3, and each product of other product models manufactured between September 12 and September 19 are in operation. Information and operation information of each product of all other manufacturing devices and all product models are stored for each set of operation information collected during the access timing interval of the operation information collection unit 171. The same applies to the data records in the rows 404 and 405.

The production record information 122 of the storage unit 120 of the productivity evaluation device 100 records the record of how many products (sheets) of which product model are manufactured by each manufacturing device of each production line every day for a certain period of time. The information recorded in the production record information 122 is added and updated every day, and the old information after a certain period of time is discarded.

The productivity evaluation condition setting unit 111 of the calculation unit 110 of the productivity evaluation device 100 is started by the user prior to the productivity evaluation of the production equipment constituting the production line, and the user designates the production line and the production equipment to be evaluated. , Normal actual operating time data aggregation period, aggregation interval, statistical information period for setting failure tendency judgment threshold, access timing of operating information storage device, data retention period, etc. It is stored in the productivity evaluation condition parameter 123 of the unit 120.

The normal actual operating time totaling unit 112 of the calculation unit 110 of the productivity evaluation device 100 is instructed at a time when the user needs the productivity evaluation, or is automatically started at a predetermined evaluation time, and FIG. The processing of the flowchart shown in is executed.

In step S101, the productivity evaluation condition parameter 123 is accessed, and the aggregation period, aggregation interval, and evaluation target production line are set. Here, the user may specify each parameter from the operation unit 130 by initial input.

In step S102, each manufacturing apparatus number of the production line to be evaluated is sequentially selected and set in the variable i, and the process is repeatedly executed up to S109.

In step S103, each product model manufactured by the manufacturing apparatus i during the aggregation period is read from the production record information 122, sequentially selected and set in the variable j, and the process is repeatedly executed up to S108.

In step S104, all the operation information of the manufacturing equipment i and the product model j during the aggregation period without any error is read from the manufacturing equipment operation information table 173 and stored in the normal actual operation information 124 storage area.
That is, in the manufacturing equipment operation information table 173, operation information related to all product models is stored in the manufacturing equipment operation information table 173 for the storage period set in the operation information storage device. Among them, products manufactured by the manufacturing apparatus i (i = 1) during the aggregation period (for example, 3 weeks from September 11, 2017 (Monday) to October 1, 2017 (Sunday)). Only the operation information of the model j (j = 3) is read, and the data record having the error presence / absence information of 406 is excluded, and other operation information is stored in the normal actual operation information 124 storage area.

FIG. 6 shows an example of a data table of the normal performance operation information 124 storage area that is updated every time. The operation information in all the rows of 501 to 506 is all the operation information of the manufacturing apparatus i (i = 1) and the product model j (j = 3) during the aggregation period without any error.

In step S105, for each operation information stored in the normal actual operation information 124 storage area, the actual operation time from the production start time to the production end time is calculated by the equation 1 and stored in the normal actual operation information table. ..
(Number 1) (Actual operating time) = (Manufacturing end time)-(Manufacturing start time)
Since the normal actual operation information is the operation information without any error, the actual operation time without the stop time during the operation in the manufacturing process of the product is required. That is, from the cycle time from the delivery of the product to the manufacturing apparatus to the removal of the product, the operation waiting time from the delivery of the product to the manufacturing apparatus to the start of the actual work of the manufacturing apparatus, and the manufacturing. It is possible to exclude the carry-out waiting time from when the device finishes the substantial work until the product is carried out from the manufacturing device. Therefore, it is possible to exclude the operation waiting time due to the stoppage of the manufacturing apparatus during the processing of the previous product and the carry-out waiting time due to the stoppage of the manufacturing apparatus of the other previous process. As a result, the user (evaluator) can accurately recognize the change in the production state in the manufacturing apparatus to be monitored.

In step S106, the operation information of the normal actual operation information 124 storage area for which the actual operation time has been calculated is collected at the aggregation interval (for example, in this embodiment, the aggregation interval is one week, and from September 11, 2017 (Monday). September 17, 2017 (Sun), September 18, 2017 (Mon) -September 24, 2017 (Sun), September 25, 2017 (Mon) -October 1, 2017 (Sun), Divide into sets for each period). Then, for each set, the average value and standard deviation of the actual operating hours of each operating information included in each set are calculated.

In step S107, the statistical value (operating time average value, standard deviation) of the actual operating time at each aggregation interval calculated in S106 is stored in the normal actual operating time statistical result 125 storage area.
FIG. 7 shows an example of a data table stored in the normal actual operating time statistical result 125 storage area. The 125 table of normal actual operating time statistical results consists of data items of manufacturing equipment number, product model, aggregation interval, operating time average value, and standard deviation, and stores statistical values of all manufacturing equipment i and product model j in order. ..

In step S110, the normal actual operating time statistical value reporting unit 114 of the calculation unit 110 of the productivity evaluation device 100 is started, calculated by the normal actual operating time totaling unit 112, and stored in the normal actual operating time statistical result 125 storage area. Based on the statistical results obtained, the normal actual operating time statistical results are reported to the monitor of the control unit of each manufacturing apparatus and / or to the terminal at the manufacturing site.

For example, when the control unit of the manufacturing apparatus (i = 1) has a monitor, as shown in FIG. 10, a graph of the normal actual operating time statistical value transition in the product model = 3 is created, and the manufacturing apparatus (i = 1) is used. It is possible to output to the monitor of the control unit of = 1). Similarly, it is possible to output to all other manufacturing devices i. Alternatively, the normal actual operating time statistical result is output to the terminal 180 at the manufacturing site. The user at the manufacturing site can display the graph of the normal actual operating time statistical result of the desired manufacturing apparatus on the manufacturing site terminal 180 and determine the presence or absence of manufacturing variation.

The user of the productivity evaluation device 100 activates the normal actual operating time statistical value reporting unit 114 to display a graph of the normal actual operating time statistical result of all the manufacturing devices constituting all the production lines designated as the evaluation target. It can be output to the display unit 140 to determine the presence or absence of manufacturing variation.

In this embodiment, when the normal actual operating time statistical value reporting unit 114 reports the normal actual operating time statistical result, the operating time average value at a certain aggregation interval exceeds the threshold value calculated based on the past statistical information. If it is determined whether or not it is, and if an average operating time value exceeding the value occurs, it is determined that the corresponding manufacturing equipment requires maintenance, and a function for notifying the failure tendency is provided.

In order to realize the determination function based on the threshold value, the storage unit 120 of the productivity evaluation device 100 is provided with the past statistical information 126 storage area. FIG. 8 shows an example of a data table stored in the past statistical information 126 storage area. In the past statistical information 126, the normal actual operating time aggregation unit 112 stores the statistical value (operating time average value, standard deviation) of the actual operating time at each aggregation interval for a predetermined period, and the normal actual operating time statistical result 125 storage area. At the same time, all the data items of the manufacturing device number, the product model, the aggregation interval, and the average operating time value are recorded when stored in. As for the past statistical information stored in the past statistical information 126 storage area, old information that has passed a predetermined period is sequentially discarded.

The failure tendency determination threshold value setting unit 113 of the calculation unit 110 of the productivity evaluation device 100 is specified by the user at the time when the threshold value setting process is determined by the user, or is automatically updated at a preset interval. It will be activated when it is reached. The processing of the failure tendency determination threshold value setting unit 113 is represented by the flowchart of FIG.

In step S201, the productivity evaluation condition parameter 123 is accessed, the manufacturing apparatus number for which the threshold is set, and the period P (for example, 8 weeks) for which the past statistical information 126 is referred to for setting the threshold are read, and each of them is read. The product model manufactured in the manufacturing apparatus is read from the production record information 122, and the threshold setting condition is specified. Here, the user may specify each parameter from the operation unit 130 by initial input.

In step S202, the threshold value setting target manufacturing apparatus number is sequentially selected and set in the variable i, and the execution is repeated up to S207.

In step S203, the threshold setting target product models are sequentially selected and set in the variable j, and the process is repeatedly executed up to S206.

In step S204, all the past statistical data of the manufacturing apparatus i and the product model j during the threshold setting period P are read from the past statistical information 126 storage area, and the average value m of the operating time average value of the past statistical data and the standard deviation σ Is calculated.

In step S205, the threshold value S for determining the failure tendency is set by the equation 2 according to the equation 2.
(Number 2) S = m + σ
Is calculated. The calculated threshold value S is stored in the productivity evaluation condition parameter 123 storage area as a threshold value for the manufacturing apparatus i and the product model j. When the threshold value for the manufacturing apparatus i and the product model j is already stored in the productivity evaluation condition parameter 123 storage area, the threshold value is updated by the newly calculated threshold value.
The method for calculating the threshold value S does not have to be limited to the above-mentioned equation (2), and may be appropriately changed.

In the second embodiment, when the normal actual operating time statistical value reporting unit 114 reports the normal actual operating time statistical result 125, the corresponding threshold value S is read from the productivity evaluation condition parameter 123 storage area, and the normal actual operating time operation is performed. If the average operating time of the time statistics results exceeds the threshold S, the corresponding manufacturing equipment determines that maintenance is required and displays a message notifying the user of the failure tendency or an alarm. A warning is issued by ringing.

100 Productivity evaluation device 110 Calculation unit 111 Productivity evaluation condition setting unit 112 Normal actual operating time totaling unit 113 Failure tendency judgment threshold setting unit 114 Normal actual operating time statistical value reporting unit 120 Storage unit 121 Manufacturing equipment productivity evaluation program (storage) region)
122 Production record information (storage area)
123 Productivity evaluation condition parameter (storage area)
124 Normal performance operation information (storage area)
125 Normal actual operating time statistical results (storage area)
126 Past statistics (storage area)
130 Operation unit 140 Display unit 150 Communication unit 160 Network 170 Operation information storage device 171 Operation information collection unit 172 Error presence / absence determination unit 173 Manufacturing device operation information (storage area)
180 Manufacturing site terminal 200 Manufacturing equipment 201 Working area 202 Working area 203 Carrying out area 204 Product (printed circuit board)
205 Product waiting to be operated 206 Product waiting to be carried out 301 Manufacturing start time 302 Manufacturing end time 303 Error occurrence time 304 Error presence / absence judgment result

Claims (6)

In a configuration in which a plurality of manufacturing devices are connected to carry out each process of manufacturing a product in a production line, device operation information and device error information are collected from each manufacturing device to check the production status of each manufacturing device. It is a productivity evaluation system that helps you to do
Each manufacturing device has at least the manufacturing device number, product model, product ID, device operation information including the manufacturing start time and manufacturing end time for each product, and at least the time when various device errors that may cause production loss occur. It is configured to report device error information, including
Through the network, information on the manufacturing start time, manufacturing end time, and device error occurrence time for each product is collected from each manufacturing device, and the device error occurrence time is between the manufacturing start time and the manufacturing end time for each product. And the operation information storage device that stores the device operation information by adding the judgment value of the presence or absence of the device error.
From the operation information storage device, all device operation information without the judgment flag that an error occurred for each manufacturing device and product model is extracted as normal actual operation information, and for each aggregation interval arbitrarily specified by the user . With a productivity evaluation device that creates a graph of normal actual operating hours and standard deviations in a time-series transition and displays them on the display unit, on the terminal at the manufacturing site, or on the monitor of the control unit of each manufacturing equipment. ,
A productivity evaluation system characterized by being equipped with. When the productivity evaluation device outputs the average value of the normal actual operating time for each aggregation interval and the standard deviation arbitrarily specified by the user, the average value of the normal actual operating time for each aggregation interval and the predetermined period If the average value of normal actual operating hours for each aggregation interval exceeds the threshold compared to the threshold created based on past statistical information, a warning is issued to the effect that maintenance is required for the relevant manufacturing equipment. The productivity evaluation system according to claim 1. The productivity evaluation device records the average value of the normal actual operating hours for each aggregation interval arbitrarily specified by the user as past statistical information, reads out the past statistical information for a predetermined period at the time of setting the threshold value, and for each aggregation interval. Calculate the average value m and standard deviation σ of the average value of the normal actual operating hours of, and set the threshold value S by the equation 2
(Number 2) S = m + σ
The productivity evaluation system according to claim 2 , wherein the productivity evaluation system is calculated. In a configuration in which a plurality of manufacturing devices are connected to carry out each process of manufacturing a product in a production line, a computer collects device operation information and device error information from each manufacturing device to produce each manufacturing device. It is a productivity evaluation method that helps to check the condition .
Each manufacturing device has at least the manufacturing device number, product model, product ID, device operation information including the manufacturing start time and manufacturing end time for each product, and at least the time when various device errors that may cause production loss occur. It is configured to report device error information, including
A computer connected to each manufacturing device via a network
From each manufacturing device, information on the manufacturing start time, manufacturing end time, and device error occurrence time for each product is collected, and the device error occurrence time is matched between the manufacturing start time and the manufacturing end time for each product. Adds the judgment value of the presence or absence of device error, stores the device operation information, and stores it.
From the device operation information stored above, all device operation information without the determination flag for error occurrence for each manufacturing device and product model is extracted as normal actual operation information .
The average value of normal actual operating time and standard deviation for each aggregation interval specified by the user are created in a graph of time series transition, and displayed on the display unit, on the terminal at the manufacturing site, or on the control unit of each manufacturing equipment. A productivity evaluation method characterized by displaying on a monitor. When the computer outputs the average value of the normal actual operating time for each aggregation interval and the standard deviation arbitrarily specified by the user, the average value of the normal actual operating time for each aggregation interval and the past statistical information for a predetermined period are used. Compared to the threshold created based on the above, if the average value of the normal actual operating time for each aggregation interval exceeds the threshold, a warning is issued to the effect that maintenance is required for the corresponding manufacturing equipment. The productivity evaluation method according to claim 4 . The computer records the average value of the normal actual operating time for each aggregation interval arbitrarily specified by the user as past statistical information, reads out the past statistical information for a predetermined period when setting the threshold, and normally operates for each aggregation interval. Calculate the mean value m and standard deviation σ of the mean value of time, and set the threshold value S by the equation 2
(Number 2) S = m + σ
The productivity evaluation method according to claim 5 , wherein the productivity is calculated as follows.

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