JP7281613B2 - Production control device and production control method - Google Patents

Description

The present invention relates to a production control apparatus and a production control method for managing information relating to production in a production line that processes workpieces.

2. Description of the Related Art In a production line composed of a plurality of production facilities that perform production work on workpieces, it is desired that production be performed by an optimum number of workers. Patent Document 1 describes the optimization of the number of production facilities that make up a production line and the number of workers who work on the production line by simulation, taking into consideration medium- to long-term production volume and production costs. .

JP-A-2000-112504

By the way, on a production line, there are times when workers need to move to production equipment to deal with problems such as running out of parts or equipment errors, which can occur simultaneously on multiple production equipment. Even if there is an assigned worker, the production facility may stop due to the absence of a worker who can handle it. However, the prior art including Patent Literature 1 does not disclose a method for accurately simulating such stoppage of production equipment. There was room for further improvement.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a production control apparatus and a production control method capable of estimating the downtime of production equipment due to the absence of available workers.

The production management apparatus of the present invention includes a production plan including the scheduled production time of a production line equipped with production equipment for processing a workpiece, equipment information of the production equipment, and worker information including information on whether or not workers can respond to work. and an estimating unit for estimating the downtime of the production facility due to the absence of the worker based on an improvement plan extracting unit for extracting an improvement plan for reducing the time, and a display unit displaying the improvement plan .
Another production management device of the present invention includes a production plan including the scheduled production time of a production line equipped with production equipment for processing a work, equipment information of the production equipment, and information on whether or not a worker can respond to work. and an estimating unit for estimating the stoppage time of the production facility due to the absence of the worker based on the information, and the availability information is the availability of the worker who can handle the work that occurred during the scheduled production time. The number of workers is included, and the estimating unit estimates the stop time when work exceeding the number of workers occurs .

The production management method of the present invention includes a production plan including the scheduled production time of a production line equipped with production equipment for processing a work, equipment information of the production equipment, and worker information including information on whether or not workers can respond to work. Estimate the stoppage time of the production equipment due to the absence of the worker based on, and reduce the downtime according to the type of work that causes the stoppage of the production equipment due to the absence of the worker and extracting an improvement proposal to be made, and displaying the improvement proposal .
Another production control method of the present invention includes a production plan including the scheduled production time of a production line equipped with production equipment for processing a work, equipment information of the production equipment, and information on whether or not a worker can respond to work. Based on the information, the stoppage time of the production equipment due to the absence of the worker is estimated, and the availability information includes the number of workers who can handle the work that occurred during the scheduled production time. and the estimating unit estimating the stop time when the number of workers exceeds the number of workers .

According to the present invention, it is possible to estimate the downtime of production equipment due to the absence of available workers.

1 is an explanatory diagram of the configuration of a component mounting system according to an embodiment of the present invention; FIG. FIG. 1 is an explanatory diagram of the configuration of a component mounting line provided in a component mounting system according to an embodiment of the present invention; FIG. 1 is an explanatory diagram of the configuration of a component mounting apparatus provided in a component mounting line according to an embodiment of the present invention; 1 is a block diagram showing the configuration of a production control device according to one embodiment of the present invention; (a) and (b) diagrams showing examples of work schedules of workers stored in the production control apparatus according to the embodiment of the present invention. FIG. 4 is a diagram showing an example of a simulation result screen for each event displayed on the display unit provided in the production control apparatus according to the embodiment of the present invention; FIG. 11 is a diagram showing an example of a simulation result screen for daily tabulation displayed on a display unit provided in a production control apparatus according to an embodiment of the present invention; FIG. 4 is a diagram showing an example of a simulation result screen of period aggregation displayed on the display unit provided in the production control apparatus according to the embodiment of the present invention; 1 is a diagram showing a flow of a production control method (improvement plan extraction method) according to an embodiment of the present invention; FIG. 4 is a diagram showing an example of an improvement proposal screen displayed on a display unit provided in a production control device according to an embodiment of the present invention; A diagram showing a flow of a production control method according to an embodiment of the present invention.

An embodiment of the present invention will be described in detail below with reference to the drawings. The configuration, shape, and the like described below are examples for explanation, and can be changed as appropriate according to the specifications of the component mounting system, component mounting line, production control device, printing device, component mounting device, and the like. In the following, the same reference numerals are given to the corresponding elements in all the drawings, and redundant explanations are omitted. In FIG. 2, the left side of the paper is called the upstream side in the substrate transport direction, the right side of the paper is called the downstream side of the substrate transport direction, the lower side of the paper is called the front side, and the upper side of the paper is called the rear side.

First, the configuration of a component mounting system 1 will be described with reference to FIG. The component mounting system 1 has a configuration in which three component mounting lines L1 to L3 arranged on a floor F are connected by a wired or wireless communication network 2 and managed by a line management computer 3. FIG. Each of the component mounting lines L1 to L3 is configured by connecting a plurality of production facilities including component mounting apparatuses, as will be described later, and has a function of producing mounted boards on which components are mounted. Note that the number of component mounting lines provided in the component mounting system 1 does not need to be two, and may be one, two, or four or more.

Production equipment constituting each component mounting line L1 to L3 is connected to a line management computer 3 via a communication network 2, respectively. The status of each production facility during production work is sequentially transmitted to the line management computer 3 so that the line management computer 3 can know the status of each production facility. For example, the remaining number of components supplied by the component mounter, the status of component replenishment work performed by the component mounter, the status of device errors occurring in the production equipment and the recovery work by workers, etc. are stored in the line management computer 3. Collected. Also, in the line management computer 3, it is possible to confirm the content of an apparatus error that has occurred in the production equipment of the component mounting lines L1 to L3 and perform remote recovery work.

The component mounting system 1 includes a production control device 4, which is a computer connected to a communication network 2. FIG. The production control device 4 executes various simulations relating to the production of mounted boards in the component mounting lines L1 to L3, creates production plans, creates various parameters used in the production equipment, and the like. Note that the production control device 4 may not be provided on the floor F, and may be provided on a remote general control floor (not shown) via the communication network 2 .

Next, with reference to FIG. 2, the detailed configuration of the component mounting lines L1 to L3 will be described. The component mounting lines L1 to L3 have the same configuration, and the component mounting line L1 will be described below. The component mounting line L1 is connected to production equipment having a transport section 5 that transports substrates (workpieces) from the upstream side to the downstream side. The transport units 5 connected to each other on the component mounting line L1 constitute a front transport lane 5F and a rear transport lane 5R. That is, the component mounting line L1 includes a front transport lane 5F and a rear transport lane 5R in parallel.

The front transport lane 5F includes, from upstream to downstream, a substrate supply device M1, a printing device M2, a substrate sorting device M3, a component mounting device M4, a component mounting device M5, a component mounting device M6, a conveyor device M7, and a substrate. A sorting device M8, a reflow device M9, an inspection device M10, and a substrate recovery device M11 are connected. On the rear transport lane 5R, from the upstream side to the downstream side, there are a substrate supply device M12, a substrate reversing device M13, a printing device M14, a substrate sorting device M3, a component mounting device M4, a component mounting device M5, and a component mounting device M6. , a conveyor device M7, a substrate sorting device M8, a reflow device M15, an inspection device M16, and a substrate recovery device M17.

In FIG. 2, substrate supply apparatuses M1 and M12 each include a storage unit such as a rack for storing a plurality of substrates, and supply the substrates taken out from the storage unit to downstream production equipment. The printers M2 and M14 print (deposit) solder on the electrodes of the board carried in from the upstream side through a mask. Note that the printers M2 and M14 may have a configuration in which solder is deposited on the substrate by a dispenser. The substrate sorting devices M3 and M8 each have a sorting mechanism having a transfer section 5 that receives substrates from the upstream side and carries them out to the downstream side. The substrate sorting device M3 has two sorting mechanisms, and the substrate sorting device M8 has one sorting mechanism.

The front sorting mechanism of the substrate sorting device M3 moves back and forth between the front transport lane 5F on the upstream side and the rear transport lane 5R on the downstream side (arrow a). The sorting mechanism on the rear side of the substrate sorting device M3 moves back and forth between the rear transport lane 5R on the upstream side and the front transport lane 5F on the downstream side (arrow b). The sorting mechanism of the substrate sorting device M8 includes an upstream front transport lane 5F and a rear transport lane 5R, and moves back and forth between the downstream front transport lane 5F and the rear transport lane 5R (arrow c). In accordance with commands from the line management computer 3 or the like, the board sorting devices M3 and M8 distribute the boards received from the front transport lane 5F or the rear transport lane 5R on the upstream side to the front transport lane 5F or the rear transport lane 5R on the downstream side. Distribute and carry out.

In FIG. 2, the component mounting apparatuses M4 to M6 are provided with a transport section 5 forming a front transport lane 5F and a transport section 5 forming a rear transport lane 5R. Mount the components on the printed circuit board. The conveyor device M7 receives the board from the front transport lane 5F on the upstream side, adjusts the timing, and carries it out to the front transport lane 5F on the downstream side. In addition, the conveyor device M7 receives the substrate from the rear transport lane 5R on the upstream side, adjusts the timing, and carries it out to the rear transport lane 5R on the downstream side. The reflow devices M9 and M15 heat the board on which the components are mounted while transporting the board from the upstream side to the downstream side to melt and then solidify the solder to solder the components to the board.

The inspection apparatuses M10 and M16 observe the state of the components soldered to the substrate by the built-in camera, and inspect whether or not they satisfy a predetermined standard. The substrate recovery apparatuses M11 and M17 are provided with storage units such as racks for storing a plurality of substrates, and receive substrates carried out by production equipment on the upstream side and recover them in the storage units. The substrate reversing device M13 reverses the substrate received from the upstream side according to a command from the line management computer 3 or the like, or conveys the substrate downstream without reversing it. For example, when mounting a component on the back surface of the board, the board is turned upside down by the board turning device M13.

In the component mounting line L1, a mounting board is produced by carrying out production work on the board while transferring the board from the upstream side to the downstream side production equipment via the front transport lane 5F and the rear transport lane 5R. That is, the board is a work, and the production equipment such as the printers M2 and M14 and the component mounting machines M4 to M6 constitute a production line (component mounting line L1) for processing the work (board). In the component mounting line L1, the configuration of the production equipment can be freely changed according to the type of mounting boards to be produced and the production volume. In addition to the above-described production facilities, there are also laser marking devices that use a laser to engrave numbers and the like on substrates, conveyer devices that have a built-in mark reading function that has a camera that reads marks attached to substrates, and inspects the printing state of solder. A print inspection device or the like may be provided.

Next, referring to FIG. 3, the configuration of the component mounting apparatuses M4 to M6 will be described. The component mounting apparatuses M4 to M6 have the same configuration, and the component mounting apparatus M4 will be described here. Above the center of the front surface of the component mounting apparatus M4, there is a mounting head 6 that mounts components on the board, and a head moving mechanism (not shown) that horizontally moves the mounting head 6, so that the operator does not accidentally touch the movable parts. A protective shutter 7 is installed. When an operator performs recovery work, the shutter 7 is opened and the mounting head 6 and the like inside the apparatus are treated. A component supply section 8 is provided below the center of the front surface of the component mounting apparatus M4 (below the shutter 7).

A carriage 10 that holds a plurality of tape feeders 9 as a component supply device in parallel is attached to the upper part of the component supply unit 8 . Below the tape feeder 9 in the carriage 10, a plurality of reels 11 for winding and storing a component supply tape for storing components are held in parallel. The tape feeder 9 feeds the components stored in the component supply tape to the component mounting apparatus M4 in order while conveying the component supply tape pulled out from the reel 11 inside. When the remaining number of components stored in the component supply tape becomes small, a new component supply tape is spliced to the rear end of the component supply tape that is supplying the components, or a new component supply tape is inserted into the tape feeder 9. Then, the operator performs a component replenishment work for replenishing the tape feeder 9 with components.

In FIG. 3, an operation unit 12 is provided on the upper right portion of the front surface. The operation unit 12 is provided with a touch panel 13 and various operation buttons 14 . The touch panel 13 displays various information, warning information, input buttons, etc. on its display portion. The operator operates the operation buttons 14 and the input buttons displayed on the touch panel 13 to operate the component mounting apparatus M4. The component mounting apparatus M4 is provided with a shutter 7, a component supply section 8, and an operation section 12 on the rear side as well as on the front side.

In FIG. 1, in the component mounting lines L1 to L3, model switching is performed to switch the type (model) of the mounting substrate to be produced based on the production plan. At the time of model switching, in the printers M2 and M14, the operator exchanges masks, changes printing conditions, and the like. In the component mounting apparatuses M4 to M6, operators perform model switching work such as replacement of the carriage 10, replacement of component suction nozzles, and change of mounting data. Hereinafter, the preparatory work for model switching in the component mounting lines L1 to L3 will be referred to as "internal setup".

In addition, while the mounting boards are being produced in the component mounting lines L1 to L3, a preparatory work of setting the tape feeder 9 and the reel 11 to be used for the next production of the mounting board on the spare carriage 10 is performed. performed by Hereinafter, the preparatory work for model switching outside the component mounting lines L1 to L3 will be referred to as "outside setup".

Next, referring to FIG. 4, the configuration of the production management device 4 will be described. The production control device 4 includes a processing unit 20 , a production plan storage unit 24 as a storage device, a line information storage unit 25 , an operator information storage unit 26 , an input unit 27 and a display unit 28 . The processing unit 20 is a data processing device such as a CPU, and includes an estimation unit 21, a display processing unit 22, and an improvement plan extraction unit 23 as internal processing units. Note that the production control device 4 does not need to be composed of one computer, and may be composed of a plurality of devices. For example, all or part of the storage device may be provided in the cloud via a server.

The input unit 27 is an input device such as a keyboard, touch panel, mouse, etc., and is used for inputting operation commands and data. The display unit 28 is a display device such as a liquid crystal panel, and displays various data stored in each storage unit, as well as various information such as an operation screen for operation by the input unit 27, a simulation result screen, and an improvement proposal screen. display on the screen.

4, the production plan storage unit 24 stores production plan information 24a, production data 24b, estimated results 24c, and the like. The production plan information 24a includes information specifying the product type to be produced, the number of production, the component mounting lines L1 to L3 for producing the mounted boards, and the front transport lane 5F or the rear transport lane 5F for transporting the boards for each lot of mounted boards to be produced. A production plan including information specifying the side transport lane 5R, production order, production schedule (scheduled production date, scheduled production start time, scheduled production end time), etc. is stored. The production data 24b stores information necessary for component mounting work, such as component types and mounting positions of components to be mounted on boards, for each type of mounted board to be produced. That is, the production data 24b is data for processing the board (work).

The line information storage unit 25 stores line configuration information 25a, facility information 25b, and the like. The line configuration information 25a stores information on the configuration of the production line, such as the type of production equipment that constitutes each of the component mounting lines L1 to L3 and the order in which they are connected. The equipment information 25b includes, for each production equipment constituting the component mounting lines L1 to L3, the equipment number, the type of production equipment, the number of conveying units 5, the work area, and the work per mounted board produced for each product type. Information related to time (equipment tact time), frequency of occurrence of equipment errors (occurrence probability), etc. is stored. That is, the equipment information 25b includes the probability of occurrence of work such as recovery work for equipment errors that occur in the production equipment. The probability of occurrence is a value set based on expected values and actual values.

In FIG. 4, the worker information storage unit 26 stores worker information 26a of workers who are in charge of work on the floor F for each worker. The worker information 26a includes an identification number for identifying the worker, a work schedule including break times, the work scope of the worker, work authority, work ability, and the like. The scope of work is information specifying the component mounting lines L1 to L3, production facilities, etc. in charge. Moreover, when a robot is included in the worker, information for determining whether the worker is a human or a robot may be included. The worker information storage unit 26 also stores worker information 26a of workers who are remotely in charge of work other than the floor F for each worker.

The work authority is information as to whether or not the work that occurs on the floor F is executable. For example, whether or not restoration work, parts replenishment work, external setup work, etc. can be executed is stored. The work capacity is information such as average work time and movement speed for each type of work performed in production equipment. That is, the worker information 26a includes working hours for each type of work performed in the production facility. Note that the work ability may be a class or the like indicating the skill level of the worker. Also, the work time for each type of work may be changed based on the work capacity.

Here, with reference to FIG. 5(a), an example of the work schedule included in the worker information 26a and the operation schedule of the production equipment will be described. In the example of FIG. 5A, the work start time is 8:30, the work end time is 18:30, and the working hours are 10 hours. In addition, of the working hours, 20 minutes from 8:30 to 8:50 is "Morning meeting / inspection", 15 minutes from 10:30 to 10:45 is "Break 1", 1 hour from 12:00 to 13:00 is "Break 2", and 15 minutes from 15:00 to 15:15 is "Break 3".

During the "morning assembly/inspection", the operation of the production facilities of the component mounting lines L1 to L3 is stopped. On the other hand, the operation of the production equipment is continued during the "break 1", "break 2", and "break 3". In other words, "Break 1", "Break 2", and "Break 3" are working hours, but are non-productive working hours during which production is not engaged. In this way, the worker information 26a stores the worker's working hours and the working schedule including non-productive working hours within the working hours. In addition to rest, morning meetings, and inspections, non-production work hours include desk work and meetings. The production management device 4 may acquire the work schedule from a core system such as ERP.

In FIG. 5(b), the working hours of four workers W1 to W4 and the operation schedule of the production equipment are represented in a graph with the time on the horizontal axis. In this example, four workers W1 to W4 have the same work schedule. The work area is assigned such that worker W1 is in charge of component mounting line L1, worker W2 is in charge of component mounting line L2, worker W3 is in charge of component mounting line L3, and worker W4 is in charge of external setup work. .

In FIG. 4, the estimating unit 21 performs the planned production of the mounted boards specified by the production plan information 24a and the production data 24b in the configuration of the component mounting lines L1 to L3 set by the line configuration information 25a and the equipment information 25b. Simulate (simulate) the production situation when producing only the number of sheets. Specifically, the estimating unit 21 starts from the substrate supply apparatuses M1 and M12, performs the production work of the apparatus takt time in each production facility while delivering the substrates downstream, and recovers the substrates to the substrate recovery apparatuses M11 and M17. Simulate the production situation up to completion.

At that time, the estimating unit 21 detects the occurrence of work by the workers W1 to W4, such as the occurrence of component replenishment work based on component consumption in the component mounters M4 to M6, and the recovery work based on the probability (frequency) of device error occurrence. Predict. Then, the estimation unit 21 estimates the stoppage time of the production equipment due to the absence of the workers W1 to W4 based on the predicted occurrence of work and information on whether the workers W1 to W4 can handle the work.

In FIG. 4, the estimated stop time includes the type of work (work type), information specifying the device where the work occurred, the time when the work was stopped (stop time), the time when the work was restored (recovery time), and the workers W1 to W4. is stored in the production plan storage unit 24 as an estimation result 24c in association with the absence time during which the operator cannot perform the work, the start time of movement to the work position, the response time required for the work, and the like.

The availability information used for estimation includes rest times (non-productive working hours within working hours) of workers W1 to W4, the number of workers W1 to W4 who are in charge of the device where the work occurred, and the like. . That is, the availability information includes the working hours of workers W1 to W4, the non-production working hours within the working hours, and the number of workers during the scheduled production hours. Then, the estimating unit 21 estimates that the production facility will stop (estimating the stop time) when the work exceeding the number of workers occurs.

In this way, the estimating unit 21 calculates the production plan (production plan information 24a) including the production schedule time of the production line (component mounting lines L1 to L3), the equipment information 25b of the production equipment, and the work of the workers W1 to W4. Based on the worker information 26a including information on whether or not the workers W1 to W4 are available, and the production data 24b for processing the workpiece (substrate), the downtime of the production facility due to the absence of the workers W1 to W4 is estimated. The simulation by the estimating unit 21 is performed under a plurality of scenarios in which the number of workers W1 to W4 arranged on the floor F, work schedules, etc. are changed, and under production conditions for a long period of time (for example, one week).

In FIG. 4, the display processing unit 22 statistically processes, processes, etc. the estimation result 24c and displays it on the display screen 28a of the display unit 28. FIG. The display processing unit 22 includes an event processing unit 22a, a unit totalization processing unit 22b, a period totalization processing unit 22c, and the like. The event-by-event processing unit 22a causes the display screen 28a to display the events such as stoppage of the production facility estimated by the estimation unit 21 in order of time of occurrence. The unit aggregation processing unit 22b aggregates the events such as stoppage of the production equipment estimated by the estimation unit 21 in units of lots, hours, or days, and displays them on the display screen 28a. In the following, an example in which events are totaled on a day-by-day basis will be described. The period aggregation processing unit 22c aggregates the events for a predetermined period, such as stoppage of the production equipment estimated by the estimation unit 21, and displays the events on the display screen 28a.

Here, the simulation result screen 30 for each event displayed on the display screen 28a by the processing unit 22a for each event will be described with reference to FIG. The simulation result screen 30 includes a production date selection area 31 , a line selection area 32 and a result display area 33 . When the production date selection area 31 is operated using the input unit 27, the production date of the simulation result displayed in the result display area 33 is selected. When the input section 27 is used to operate the line selection area 32, the component mounting lines L1 to L3 of the simulation results displayed in the result display area 33 are selected. Here, the simulation result of the component mounting line L1 on September 3, 2018 is selected.

The result display area 33 includes a “number” column 34 , an “equipment information” column 35 , an “operator information” column 36 and a scroll bar 37 . In the "number" column 34, stoppages (events) of production facilities predicted to occur under the conditions selected in the production date selection area 31 and the line selection area 32 are numbered in chronological order. The "facility information" column 35 includes an "event" column 35a, a "facility" column 35b, a "lane" column 35c, a "stop time" column 35d, a "recovery time" column 35e, a "stop time" column 35f, and a "stop Total Time" column 35g is included. The "worker information" column 36 includes an "absence time" column 36a, a "movement start" column 36b, and a "response time" 36c. By operating the scroll bar 37 using the input unit 27, the contents displayed in the result display area 33 are changed (scrolled).

In FIG. 6, the "event" column 35a displays information specifying an event (work type) predicted to occur. The events include "out of parts" in which the component mounters M4 to M6 stop due to component replenishment, "error stop" in which the component mounters M4 to M6 stop due to recognition errors, adsorption errors, etc., and solder replenishment of the printers M2 and M14. There is a "solder supply stop" that stops due to

The "Equipment" column 35b displays information specifying the production equipment predicted to stop. Here, component mounting apparatus M4 is "mounter 1", component mounting apparatus M5 is "mounting machine 2", component mounting apparatus M6 is "mounting machine 3", printer M2 is "printer 1", printer M14 is "Printer 2" is displayed. The "lane" column 35c displays information specifying the transport lane of the production equipment predicted to stop. Here, "1" is displayed for the front transport lane 5F, and "2" is displayed for the rear transport lane 5R.

In FIG. 6, the "stop time" column 35d displays the predicted time (stop time) when the production facility will stop. The "recovery time" 35e displays the predicted time (recovery time) at which the production facility will be recovered from the stop due to the work of the workers W1 to W4. The "stop time" 35f displays the predicted stop time of the production equipment (stop time). The stop time is the time from the stop time to the recovery time. In the "total downtime" column 35g, the total downtime of the production equipment predicted to occur under the conditions selected in the production date selection area 31 and the line selection area 32 is displayed.

The "absence time" column 36a displays the time during which the workers W1 to W4 are resting or are unable to respond to other work and the production facility is stopped, that is, the absence time of the workers W1 to W4. The "movement start" column 36b displays the time (movement start time) at which the workers W1 to W4 start to move to the working positions. The "response time" 36c displays the time (response time) from when the workers W1 to W4 start moving to when the work is finished. That is, the response time includes the travel time of workers W1 to W4. In addition, the downtime includes the time from when the production facility stops until workers W1 to W4 become available (absence time), and the time from when workers W1 to W4 become available until they move to their work positions (movement time). time) and time to perform recovery work (work time).

In FIG. 6, error stop and solder supply stop are events that stop the production facility when they occur. In other words, even if there are workers W1 to W4 available at the time the event occurs (no absence time), the production facilities are stopped until the restoration work is completed. Furthermore, when an event occurs during break time (non-productive working time) like error stop with "14" in "number" column 34 indicated by dashed line 39, the time until the break ends becomes absence time. Adds to stop time.

On the other hand, the parts replenishment work for the component mounters M4 to M6 (mounters 1 to 3) is normally executed when the remaining number of components becomes equal to or less than a predetermined number, and the component mounters M4 to M6 do not stop. . However, if a plurality of component replenishing operations occur intensively, the workers W1 to W4 are absent during the time when the workers W1 to W4 are performing other tasks (absence time), and the component mounting apparatus M4 ∼M6 stops and runs out of parts. Events indicated by dashed lines 38 and having "10", "11", and "12" in the "number" column 34 are out-of-parts caused by concentration of parts replenishment work.

Next, with reference to FIG. 7, a simulation result screen 40 for one-day totalization displayed on the display screen 28a by the unit totalization processing unit 22b will be described. The simulation result screen 40 includes a production date selection area 41 , a line selection area 42 and a result display area 43 . The production date selection area 41 and the line selection area 42 are the same as the production date selection area 31 and the line selection area 32 of the simulation result screen 30 . Here, the simulation result of the component mounting line L1 on September 3, 2018 is selected.

The result display area 43 includes a "number of workers" column 44a, a "number of production" column 44b, an "end time" column 45, an "operating time" column 46, a "facility stop" column 47, a "worker status" column 48, A "work (details)" column 48a and a "waiting for completion" column 49 are included. The "number of workers" column 44a displays the number of workers W1 to W4 (number of workers) in charge of the component mounting line L1. The number of mounted boards (produced number) to be produced on September 3, 2018 on the component mounting line L1 is displayed in the "production number" column 44b. The "end time" column 45 displays the estimated production end time (time when the operation of the component mounting line L1 ends). The target end time (17:10) is also displayed for reference.

In FIG. 7, the "operating time" column 46 displays the estimated operating time of the component mounting line L1 (the time from the operation start time to the operation end time). A target operating time (8 hours and 20 minutes) is also displayed for reference. In the "equipment stoppage" column 47, the estimated stop time (total stop time) and frequency (stop count) of the production equipment are displayed for each production equipment and event. More specifically, the error stop and component runout of the component mounting apparatuses M4 to M6 (mounting machines), and the total stop time and the number of stop times of solder supply stoppages of the printers M2 and M14 (printing machines) are displayed.

In the "worker status" column 48, the estimated working hours of workers W1 to W4 (total working hours), resting hours (total resting hours), and non-productive working hours are shown. The amount of time that there is no work to be executed and is waiting for work (total work waiting time) and the ratio of each time to the operating time are displayed. The "work (details)" column 48a displays the breakdown of the estimated work time. Specifically, the time for the morning meeting and inspection, the total time for parts supply work (including running out of parts), the total time for error recovery (including error stop and solder supply stoppage), and traveling for work The total time and the percentage of the working time each time is displayed.

The "Waiting for end" column 49 displays the waiting time (ending waiting time) from the end of the operation of the component mounting line L1 to the end of the working hours of the workers W1 to W4. In this way, on the display screen 28a (“work (details)” column 48a) of the display unit 28, each work type (morning meeting/inspection, parts supply, error recovery, movement, etc.) of the estimated workers W1 to W4 is displayed. is displayed.

Next, with reference to FIG. 8, a simulation result screen 50 for period aggregation displayed on the display screen 28a by the period aggregation processing unit 22c will be described. The simulation result screen 50 includes a production start date selection area 51 , a production end date selection area 52 and a result display area 53 . By operating the production start date selection area 51 and the production end date selection area 52 using the input unit 27, the simulation result period (start date to end date) displayed in the result display area 53 is selected. Here, the period from September 4, 2018 to September 8, 2018 is selected.

In the result display area 53, simulation results of production of mounted boards by the three component mounting lines L1 to L3 arranged on the floor F estimated by the estimation unit 21 based on a plurality of scenarios are displayed in the selected period. aggregated and displayed. The result display area 53 includes a "number" column 54, a "number of workers" column 55, a "total operating time" column 56, a "facility stop" column 57, an "error stop" column 58, and a "parts out" column 59. is A “number” column 54 displays a number that specifies a simulation scenario. Here, simulation results of two scenarios are displayed in which the number of workers W1 to W4 placed on the floor F is changed to four and five.

In the "number of workers" column 55, the number of workers W1 to W4 arranged on the floor F (number of workers) is displayed. The "total operating time" column 56 displays the total operating time (total operating time) of the three component mounting lines L1 to L3. The "equipment stoppage" column 57 displays the total stoppage time during which the production equipment is stopped, and the ratio of the total stoppage time to the total operating time. The "error stop" column 58 displays the total and number of absence times and the total and number of response times when the production facility is stopped due to an error. The "out of parts" column 59 displays the total and number of absence times and the total and number of response times when the component mounting apparatuses M4 to M6 stop due to lack of parts. In this manner, the display screen 28a of the display unit 28 ("equipment stoppage" column 57) displays the estimated percentage of the stoppage time of the production equipment.

In FIG. 4, the improvement plan extraction unit 23 performs an improvement to improve the production efficiency (operating rate of production equipment) of the production of mounted boards by the component mounting lines L1 to L3 based on the estimation result 24c estimated by the estimation unit 21. A proposal is extracted, and the extracted improvement proposal is displayed on the display unit 28 .

An improvement plan extraction method (production control method) for extracting an improvement plan by the improvement plan extraction unit 23 will now be described along the flow of FIG. First, the improvement plan extraction unit 23 acquires the estimation result 24c from the production plan storage unit 24 (ST1). In proposing an improvement plan, the estimation results 24c including simulation results for a certain period (for example, one week) are used so that a general improvement plan can be extracted. Next, the improvement plan extraction unit 23 determines whether or not the stoppage time is equal to or longer than a predetermined period (for example, 10% of the operating time) (ST2). If the stop time is less than the predetermined time (No in ST2), the improvement plan extraction unit 23 ends the improvement plan extraction because there is no proposed improvement plan.

If the stoppage time is longer than the predetermined time (Yes in ST2), the improvement plan extraction unit 23 determines that the ratio of workers W1 to W4 working during working hours (worker operation rate) is predetermined (for example, the working time 80%) or less (ST3). If the worker operating rate is below a predetermined level (Yes in ST3), but the absence time is less than a predetermined number (for example, 20% of the operating time) (No in ST4), the improvement plan extraction unit 23 does not have any improvement plan to propose. Finish extraction of improvement plan.

In FIG. 9, if the worker operating rate is higher than a predetermined value (No in ST3), or if the worker operating rate is less than a predetermined value (Yes in ST3) but the absence time is greater than a predetermined value (Yes in ST4), improvement proposals The extraction unit 23 extracts the improvement plan described below (ST5 to ST9). That is, if the reason for the long absence time is the lack of parts (Yes in ST5), the improvement plan extraction unit 23 extracts the introduction of a parts supply support system or the introduction of a large reel as an improvement plan, and displays it on the display unit 28. An improvement plan is displayed (proposed) (ST6).

In other words, we propose the introduction of a parts supply support system that judges that the cause of stoppage of production equipment is the concentration of parts supply work, and appropriately instructs the timing of parts supply so as not to concentrate parts supply. Alternatively, if a parts supply support system has already been introduced, it proposes optimization such as advancing the timing of parts supply instructions. Alternatively, by increasing the size of the reel 11 for winding and storing the component supply tape, it is proposed to reduce the frequency of component supply work and improve production efficiency.

Here, an example of the improvement proposal screen 60 displayed on the display screen 28a of the display unit 28 will be described with reference to FIG. The improvement proposal screen 60 includes a proposal display area 61 . In the proposal display area 61, the improvement plan extracted by the improvement plan extractor 23 is displayed as text. Here, introduction of a parts supply support system is proposed.

In FIG. 9, if the cause of the long absence time is not out of parts (No in ST5) but error stop (Yes in ST7), the improvement plan extraction unit 23 introduces an automatic error recovery system or increases the number of workers. is extracted as an improvement plan, and the improvement plan is displayed (proposed) on the display unit 28 (ST8). In other words, we propose the introduction of an automatic error recovery system that automatically recovers from an error stop by judging that the prolongation of the downtime of the production equipment is due to the shortage of the man-hours of the workers W1 to W4. As a result, the working hours of workers W1 to W4 can be reduced. Alternatively, it is proposed to add workers W1 to W4 who are responsible for recovering from the error stop in the line management computer 3 and to increase the number of workers W1 to W4 who are in charge of the recovery work.

If the cause of the long absence time is not an error stop (No in ST7), the improvement plan extraction unit 23 extracts the adjustment of the break time or the adjustment of the production plan as an improvement plan, and displays the improvement plan on the display unit 28. It is displayed (proposed) (ST9). In other words, it is proposed to change the break time or shift the break time for each of the workers W1 to W4 to reduce the absence time of the workers W1 to W4 caused by the break, thereby reducing the stop time. In addition, by adjusting the production plan, we propose to reduce the concentration of work and the stoppage of production equipment.

The reason for the long absence time is neither out of parts nor error stop, so the following can be cited. In other words, while the workers are taking a break (although it is not enough time for the above-mentioned ST6 and ST8 to be absent), parts run out or an error stop occurs, and there are no or few workers to deal with it, so the equipment stoppage occurs.

In this way, the improvement plan extracting unit 23 selects an improvement plan for reducing the stoppage time according to the type of work (running out of parts, error stoppage) that causes the stoppage of production equipment due to the absence of workers W1 to W4. Extract. Further, the improvement plan extraction unit 23 extracts improvement plans for reducing the work time according to the type of work performed by the workers W1 to W4. As a result, an optimal improvement proposal for production efficiency (operating rate of production equipment) corresponding to the configuration of the component mounting system 1 including the component mounting lines L1 to L3, the work schedule of the workers W1 to W4 (worker information 26a), etc. can be proposed.

Next, along with the flow of FIG. 11, a production control method including estimating the stoppage time of the production equipment by the production control device 4 will be described. In the production control device 4, it is assumed that the estimating section 21 is simulating the production of mounted boards in the component mounting lines L1 to L3 (No in ST11). When it is predicted in the simulation by the estimating unit 21 that work has occurred in the production equipment of the component mounting lines L1 to L3 (Yes in ST12), the estimating unit 21 determines that there are workers W1 to W4 corresponding to the work that has occurred. It is determined whether or not to do so (ST13). That is, it is determined whether or not the availability information of the workers W1 to W4 is available, or whether the number of workers included in the availability information is one or more or zero.

If there are no available workers W1 to W4 (No in ST13), the stop time and absence time are counted for each error stop or parts shortage. The estimation unit 21 continues the simulation and waits until the workers W1 to W4 become available. The time until workers W1 to W4 become available is the absence time. When there are workers W1 to W4 who can handle the work, or when the workers W1 to W4 become available (Yes in ST13), the work is carried out (ST14). Next, the estimating section 21 associates the work that occurred with the stop time, the absence time, the response time, etc., and stores them as an estimation result 24c (ST15), returning to (ST11) to continue the simulation.

That is, a production plan (production plan information 24a) including the scheduled production time of a production line (component mounting lines L1 to L3) equipped with production equipment for processing a workpiece (board), and equipment information (equipment information 25b) of the production equipment. , and the worker information 26a including information on whether or not workers W1 to W4 can handle the work, the downtime of the production facility due to the absence of the workers W1 to W4 is estimated (ST15). When the simulation ends (Yes in ST11), the display processing section 22 displays the simulation result screens 30, 40, 50 on the display screen 28a of the display section 28 based on the estimation result 24c (ST16) (see FIGS. 6 to 8). ). Next, the improvement plan extraction section 23 executes the improvement plan extraction (ST1 to ST9) shown in FIG. 9, and displays the improvement plan on the display screen 28a of the display section 28 (ST17).

As described above, the production management device 4 of the present embodiment includes a production plan (production plan information 24a) including the scheduled production time of production lines (component mounting lines L1 to L3) equipped with production facilities for processing workpieces, and , based on the equipment information (equipment information 25b) of the production equipment and the worker information 26a including information on whether the workers W1 to W4 can handle the work, the downtime of the production equipment due to the absence of the workers W1 to W4 is provided with an estimation unit 21 for estimating This makes it possible to estimate the stoppage time of the production equipment due to the absence of workers W1 to W4 who can respond.

The above has been described based on one embodiment of the present invention. Those skilled in the art will understand that this embodiment can be modified in various ways in terms of the types and combinations of products (workpieces) produced (processed) on the production line, and that such modifications are within the scope of the present invention. It is about to be done. For example, the production line may be an assembly line for assembling electronic devices or a food processing line for manufacturing processed food products. Further, the workers W1 to W4 do not have to be humans, and may be robots capable of moving and working. For example, an AGV that holds and transports parts, and a multi-axis robot that freely moves the parts held by the AGV may be provided.

INDUSTRIAL APPLICABILITY The production control apparatus and production control method of the present invention have the effect of estimating the stoppage time of production equipment due to the absence of available workers, and are useful in the field of mounting components on boards. .

4 production control device L1~L3 parts mounting line (production line)
M2, M14 printing equipment (production equipment)
M4~M6 Component Mounting Equipment (Production Equipment)

Claims (19)

Based on the production plan including the scheduled production time of the production line equipped with the production equipment for processing the work, the equipment information of the production equipment, and the worker information including information on whether the worker can handle the work, an estimating unit for estimating the stoppage time of the production equipment due to absence ;
an improvement plan extraction unit that extracts an improvement plan for reducing the stoppage time according to the work type that causes the stoppage of the production equipment due to the absence of the worker ,
The production control device, wherein the display unit displays the improvement plan . 2. The production management device according to claim 1, wherein said estimation unit estimates said stoppage time based on production data for processing said work. 3. The production management apparatus according to claim 1, wherein said equipment information includes a probability of occurrence of work with respect to errors occurring in said production equipment. 4. The production management apparatus according to claim 1, wherein said worker information includes work hours for each type of work performed in said production equipment. 5. The production management apparatus according to claim 1, wherein said availability information includes working hours of said worker and non-productive work hours within said working hours. The availability information further includes the number of workers at the scheduled production time,
6. The production management apparatus according to claim 1, wherein said estimation unit estimates said stoppage time when work exceeding said number of workers occurs. 7. The production management apparatus according to claim 1, further comprising a display unit for displaying the estimated ratio of working time of said worker for each type of work. 8. The production management apparatus according to claim 1, wherein said production equipment for processing said workpiece is at least a printing device for depositing solder on a substrate or a component mounting device for mounting components on said substrate. Based on the production plan including the scheduled production time of the production line equipped with the production equipment for processing the work, the equipment information of the production equipment, and the worker information including information on whether the worker can handle the work, An estimating unit that estimates the stoppage time of the production equipment due to absence,
The availability information includes the number of workers who can handle the work that occurred during the scheduled production time,
The production management device, wherein the estimation unit estimates the downtime when the work exceeding the number of workers occurs. Based on the production plan including the scheduled production time of the production line equipped with the production equipment for processing the work, the equipment information of the production equipment, and the worker information including information on whether the worker can handle the work, Estimate the downtime of the production equipment due to absence ,
extracting an improvement plan for reducing the stoppage time according to the work type that causes the stoppage of the production equipment due to the absence of the worker;
A production control method, including displaying the improvement plan . 11. The production control method according to claim 10 , wherein said downtime is estimated based on production data for processing said work. 12. The production control method according to claim 10 , wherein said equipment information includes a work occurrence probability for an error occurring in said production equipment. 13. The production control method according to any one of claims 10 to 12 , wherein said worker information includes work hours for each type of work performed in said production equipment. 14. The production control method according to any one of claims 10 to 13 , wherein said availability information includes working hours of said worker and non-productive work hours within said working hours. The availability information further includes the number of workers at the scheduled production time,
15. The production control method according to any one of claims 10 to 14 , further comprising estimating said downtime when work exceeding said number of workers occurs. 16. The production control method according to any one of claims 10 to 15 , further comprising displaying the estimated percentage of said downtime. 17. The production control method according to any one of claims 10 to 16 , further comprising displaying the estimated ratio of working time of said worker for each type of work. 18. The production control method according to any one of claims 10 to 17 , wherein said production equipment for processing said workpiece is at least a printing device for depositing solder on a substrate or a component mounting device for mounting components on said substrate. Based on the production plan including the scheduled production time of the production line equipped with the production equipment for processing the work, the equipment information of the production equipment, and the worker information including information on whether the worker can handle the work, Estimate the downtime of the production equipment due to absence,
The availability information includes the number of workers who can handle the work that occurred during the scheduled production time,
The production control method, wherein the estimating unit estimates the downtime when work exceeding the number of workers occurs.

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