WO2017187509A1 - 作業支援装置、作業支援方法及び作業支援プログラム - Google Patents
作業支援装置、作業支援方法及び作業支援プログラム Download PDFInfo
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- WO2017187509A1 WO2017187509A1 PCT/JP2016/063050 JP2016063050W WO2017187509A1 WO 2017187509 A1 WO2017187509 A1 WO 2017187509A1 JP 2016063050 W JP2016063050 W JP 2016063050W WO 2017187509 A1 WO2017187509 A1 WO 2017187509A1
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- 238000000034 method Methods 0.000 title claims description 110
- 238000004519 manufacturing process Methods 0.000 claims abstract description 186
- 238000009826 distribution Methods 0.000 claims abstract description 20
- 230000008569 process Effects 0.000 claims description 98
- 238000003860 storage Methods 0.000 claims description 11
- 238000001514 detection method Methods 0.000 abstract description 8
- 239000000758 substrate Substances 0.000 description 67
- 235000019219 chocolate Nutrition 0.000 description 61
- 238000007689 inspection Methods 0.000 description 9
- 230000006870 function Effects 0.000 description 6
- 229910000679 solder Inorganic materials 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 239000006185 dispersion Substances 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0224—Process history based detection method, e.g. whereby history implies the availability of large amounts of data
- G05B23/024—Quantitative history assessment, e.g. mathematical relationships between available data; Functions therefor; Principal component analysis [PCA]; Partial least square [PLS]; Statistical classifiers, e.g. Bayesian networks, linear regression or correlation analysis; Neural networks
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- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
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- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4188—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by CIM planning or realisation
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- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
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Definitions
- This case relates to a work support device, a work support method, and a work support program.
- production completion time For production lines such as surface mount lines and devices that perform various types of production, the earlier the time (production completion time) for completing all production plans assigned in advance for each production line or device, the more cost and delivery desirable.
- Patent Documents 1 to 3 disclose techniques for determining the priority order of work.
- the chocolate stop of the device that executes the bottleneck process (the process with the lowest production capacity) is given the highest priority.
- the execution order may be determined in descending order of the influence on the bottleneck process. Further, when a plurality of chocolate stops occur simultaneously between the lines, the execution order may be determined so as to give priority to the chocolate stop operation of the line whose production completion time is expected later.
- the bottleneck process is specified based on the expected processing time of each process determined in advance in the production plan, or the production of each line is completed based on the expected processing time.
- the time can be specified.
- an object of the present invention is to provide a work support device, a work support method, and a work support program capable of determining and outputting an appropriate work priority order of work for solving a problem. To do.
- the work support device is a work support device that supports work for solving a plurality of problems occurring simultaneously in a system having a plurality of devices that produce products, wherein the plurality of problems
- An acquisition unit that acquires the performance information of the processing time required when the product produced in each of the devices at the time of occurrence in the past in each of the devices, and the prior distribution stored in the storage unit,
- An estimator that estimates the processing time required to produce the product in each of the devices based on the acquired performance information of the processing time, and a work priority of each of the devices based on the estimated processing time
- a determination unit for determining and outputting.
- FIG. 8A to FIG. 8C are diagrams (No. 1) for explaining the effect of predicting the processing time. It is a flowchart which shows the specific process of step S18 of FIG.
- FIG. 10A and FIG. 10B are diagrams (No. 2) for explaining the effect obtained by predicting the processing time. It is a figure which shows the example of a display. It is a figure which shows a modification.
- FIG. 1 schematically shows a configuration of a production system 100 according to an embodiment.
- the production system 100 of this embodiment includes a production line 70, a server 10 as a work support device, and a worker terminal 60.
- the production line 70, the server 10, and the worker terminal 60 are connected to a network 80.
- the production line 70 has a plurality of surface mounting lines 20 as shown in FIG. 2 as an example.
- the surface mounting line 20 is a line for mounting components on a printed circuit board (hereinafter simply referred to as “board”), and is a board loader, solder printing machine, printing inspection machine, mounter line, mounting inspection machine, reflow furnace.
- a visual inspection machine, an unloader, and the like are provided, and the devices are connected by a conveyor.
- the mounter line has a plurality of mounter devices for mounting components on a board.
- the substrate loader loads the substrate on the conveyor.
- the solder printing machine prints solder at a predetermined location on the substrate.
- the print inspection machine inspects the solder on the substrate.
- the board that has passed the inspection by the printing inspection machine is conveyed to a mounter line, and in the mounter line, a component such as an electronic component is surface-mounted on the printed solder on the board in each mounter device.
- the mounting inspection machine inspects whether there are any defects in the mounting of the components on the board.
- the reflow furnace fixes the component to the substrate by performing reflow on the substrate that has passed the inspection.
- the appearance inspection machine inspects the appearance of the substrate for defects.
- the unloader takes out the board that has passed the inspection from the conveyor.
- the mounter line of this embodiment shall be a line which does not have the buffer of a board
- the number of substrates processed on the apparatus is about 1 or 2. For this reason, when the equipment behind the equipment that executes the bottleneck process (process with the lowest production capacity) in the mounter line stops, the substrate processed in the bottleneck process cannot be sent to the equipment behind it.
- the apparatus that performs the bottleneck process may stop. Therefore, when considering production efficiency (reduction of production time), it is preferable that the apparatus that executes the bottleneck process and the process before the bottleneck process is stopped, as well as the apparatus that is behind the bottleneck process is stopped. Absent.
- drawing number means a set (lot) of substrates manufactured on one or more identical substrates and continuously on the same surface mounting line.
- the server 10 manages various data obtained from the production line 70 and notifies the worker terminal 60 of the production status of the production line 70. Further, the server 10 supports the worker's work by notifying the worker terminal 60 of the work timing of the worker on the production line 70.
- FIG. 3 shows the hardware configuration of the server 10.
- the server 10 includes a CPU (Central Processing Unit) 90, a ROM (Read Only Memory) 92, a RAM (Random Access Memory) 94, a storage unit (HDD (Hard Disk Drive) here) 96, a network. An interface 97 and a portable storage medium drive 99 are provided. Each component of the server 10 is connected to a bus 98.
- the CPU 90 executes a program (including a work support program) stored in the ROM 92 or the HDD 96, or a program (including a work support program) read from the portable storage medium 91 by the portable storage medium drive 99.
- the function as each part shown in FIG. 4 is implement
- achieved. 4 also shows a production plan information DB (database) 52 and a production status information DB 54 stored in the HDD 96 of the server 10.
- FIG. 4 shows a functional block diagram of the server 10.
- the CPU 90 executes the program to produce a processing time estimation unit 30 as a production plan information collection unit 30, a production status information collection unit 32, a control unit 34, a chocolate stop detection unit 36, an acquisition unit, and an estimation unit shown in FIG. 38, a bottleneck estimation unit 40, a line production completion time estimation unit 42, a work order determination unit 44, and a work order display unit 46.
- the production plan information collection unit 30 collects production plan information from the production plan information DB 52 and transmits it to the control unit 34.
- the production plan information includes information related to the production plan of each drawing number and information related to the production of each board.
- the production plan information DB 52 stores a first substrate information table 152A, a substrate processing time table 152B, a second substrate information table 152C, and the like as shown in FIG.
- the first board information table 152A is a table for managing mounter line information used for production of each drawing number in the past, information obtained at the time of production, and the like. As shown in FIG. 5, the first board information table 152A has fields of “mounter line”, “drawing number”, “board type (version number)”, “number of boards”, and “production time”.
- the “mounter line” field stores the identification information of the mounter line used for production
- the “drawing number” field stores the identification information of the produced drawing number.
- the “substrate type (version number)” field the type (version number) of the substrate of each figure number is stored, and in the “substrate number” field, the number of produced substrates is stored, and “production time”. This field stores the time required for production.
- the substrate processing time table 152B is a table for managing various information defined in the production plan. As shown in FIG. 5, the substrate processing time table 152B includes “substrate type (version number)”, “mounter line”, “mounter device number”, “processing time per substrate”, and “processing per substrate”. Each field includes “time distribution parameter” and “dispersion of processing time per substrate”. In the fields of “Substrate type (version number)”, “Mounter line” and “Mounter device number”, it is possible to indicate which type of substrate is data relating to the processing time in which mounter device of which mounter line is manufactured. Information for identification is stored. The “processing time per substrate” stores the processing time ( ⁇ 0 ) per substrate determined at the time of production planning. In “distribution parameter of processing time per substrate” and “dispersion of processing time per substrate”, the distribution parameter ( ⁇ 0 2 ) and variance ( ⁇ 2 ) per substrate determined at the time of production planning are included. ) Is stored.
- the second substrate information table 152C is a table for managing the production order of the drawing numbers in each production line 70 (mounter line).
- the second board information table 152C includes fields of “mounter line”, “order within line”, “drawing number”, “board type”, and “number of boards”.
- the “mounter line” field stores the identification information of the mounter line used for production
- the “in-line order” field contains a number indicating the figure number to be placed on the mounter line.
- the “ Figure Number” field stores the identification information of the figure number to be input
- the “Board Type” field stores the board type of the figure number
- the “Number of Boards” field indicates the production. The number of substrates to be stored is stored.
- the production status information collection unit 32 collects production status information from the production status information DB 54 and transmits it to the control unit 34.
- the production status information includes information regarding each drawing number, information regarding the production status of each substrate, and information regarding a chocolate stop that has occurred in the production line 70.
- the “choco stop” means a short stop or delay that occurs suddenly in the mounter device included in the production line 70. An operator needs to perform work (chocolate stop work) to eliminate such a phenomenon that occurs suddenly.
- FIG. 6 shows a production status table 154A for each drawing number, a production status table 154B for each substrate, and a chocolate stop information table 154C included in the production status information DB 54.
- the production status table 154A by drawing number is a table for storing the production status of each drawing number, and has fields of “drawing number”, “mounter line”, “production start time”, and “production completion time”.
- the “drawing number” field the identification information of the drawing number to be produced is stored, and in the “mounter line” field, the identification indicating the mounting line where the drawing number is produced / produced / produced is shown. Information is stored.
- the “production start time” field stores the time when the production is started, and the “production completion time” field stores the time when the production is completed. Note that the “production start time” and “production completion time” fields are blank for the figure numbers for which production has not started, and the “production completion time” field is blank for the figure numbers being produced. It has become.
- the board-by-board production status table 154B is a table for storing the production status of each board.
- the “drawing number”, “board manufacturing number”, “mounter line”, “mounter device number”, “production start time”, “production” Each field of “completion time”.
- Information for specifying the board to be produced is stored in the “drawing number” and “board manufacturing number” fields, and the board is produced in the “mounter line” and “mounter device number” fields.
- the mounted / produced mounter lines and mounter device numbers are stored.
- the “production start time” and “production completion time” fields the time at which each substrate is produced and the time at which each substrate is produced are stored. Note that the “production start time” and “production completion time” fields are blank for the figure numbers for which production has not started, and the “production completion time” field is blank for the figure numbers being produced. It has become.
- the chocolate stop information table 154C is a table for storing information about a chocolate stop, and has fields of “mounter line”, “mounter device number”, “occurrence time”, “work completion time”, and “content”.
- “mounter line” and “mounter device number” information on the mounter line and mounter device where the choke stop has occurred is stored.
- “occurrence time” field information on the time when the chocolate stop occurred is stored.
- work completion time information on the time when the choke stop work by the worker is completed is stored.
- the “content” field the contents of the chocolate stop (the reason why the mounter device stopped) are stored.
- control unit 34 comprehensively controls processing of each function (each unit) of the server 10. For example, the control unit 34 transmits the data collected by the production plan information collection unit 30 and the production status information collection unit 32 to each unit 36 to 46 at an appropriate timing, and processes the units 36 to 46 at an appropriate timing. Or let it run.
- the chocolate stop detection unit 36 detects that a chocolate stop has occurred based on the data collected by the production status information collection unit 32 from the chocolate stop information table 154C.
- the chocolate stop detection unit 36 detects that a chocolate stop has occurred when information indicating that data is newly stored in the chocolate stop information table 154C of FIG. 6 is received.
- the processing time estimation unit 38 estimates a processing time of a process executed by each mounter device of each surface mounting line 20.
- the bottleneck estimation unit 40 estimates a bottleneck process (mounter device corresponding to the bottleneck process) among the mounter lines included in each surface mounting line 20 based on the estimation result of the processing time estimation unit 38.
- the line production completion time estimation unit 42 estimates the production completion time of each surface mounting line 20. Based on the estimation results of the bottleneck estimator 40 and the line production completion time estimator 42, the work order determination unit 44 performs what kind of work (chocolate stop work) for eliminating the chocolate stop occurring at the same time. Decide what to do in order.
- the work order display unit 46 transmits the order determined by the work order determination unit 44 (work priority order) to the worker terminal 60 and causes the worker terminal 60 to display the order.
- the worker terminal 60 is a terminal that is carried by the worker or installed near the production line 70, and is a PC (Personal Computer), a tablet terminal, a smartphone, or the like.
- the worker terminal 60 includes a display, and supports the work by the worker by displaying the work order of the choke stop work determined by the server 10.
- FIG. 9 is a flowchart showing a specific process of step S18 of FIG. As a premise of this processing, it is assumed that the number of work resources (workers) for executing the choke stop work of the production line 70 is 1 (one person).
- step S10 the chocolate stop detection unit 36 waits until it detects the occurrence of a new chocolate stop.
- the chocolate stop detection unit 36 detects that a chocolate stop has occurred when information indicating that data is newly stored in the chocolate stop information table 154C of FIG. 6 is received from the production status information collection unit 32. .
- the chocolate stop detection unit 36 determines whether or not the number of chocolate stops that have not been completed is greater than one.
- the chocolate stop detection unit 36 includes information on a plurality of chocolate stops whose work completion times are not input in the chocolate stop information table 154C of FIG. 6 via the control unit 34 and the production status information collection unit 32. Check if it is. If there is information on a plurality of chocolate stops for which the work completion time has not been input, the determination in step S12 is affirmed and the process proceeds to step S14. On the other hand, if there is only one piece of information about the chocolate stop for which the work completion time has not been input, the process returns to step S10. If the number of work resources (workers) is two or more, it may be determined in step S12 whether or not the number of chocolate stops that have not been completed is greater than the work resources.
- the processing time estimation unit 38 estimates the processing time of each process (each mounter device) of each surface mounting line 20. Specifically, the processing time estimation unit 38 estimates the processing time required to process one substrate of the figure number (target figure number) currently being produced in each process.
- the processing time for one substrate in each process is estimated by MAP estimation (maximum posterior probability estimation). That is, the processing time estimation unit 38 reads the prior distribution of the average processing time based on the processing time given in the production plan from the substrate processing time table 152B in FIG. 5, and the actual processing time observed as the prior distribution. The posterior distribution of the processing time is obtained based on the observed value, and the processing time at which the obtained posterior distribution is maximized is set as the estimated value of the processing time.
- MAP estimation maximum posterior probability estimation
- the processing time of the target figure number in the target process at the production planning stage is ⁇ 0
- ⁇ 0 , ⁇ 0 2 ) is a normal distribution having an average ⁇ 0 and a variance ⁇ 0 2 .
- ⁇ 0 2 is given empirically from past data. As ⁇ 0 2 , a sufficiently large value is set as compared with ⁇ 0 when there is no standard value such as past data.
- ⁇ 0 is the value of the “processing time per substrate” field of the substrate processing time table 152B of FIG. 5, and ⁇ 0 2 is the “value of the substrate processing time table 152B of FIG. This is the value of the field “distribution parameter of processing time per substrate”.
- the observed value of n processing time of the target drawing number in the target step X 1, X 2, ..., and X n is the difference between the “production completion time” and the “production start time” in the production status table 154B for each board in FIG. 6, and the observed value X is p (X
- ⁇ ) N ( Suppose that X
- X 1, X 2, ..., X n) is the prior distribution and the observed values X 1, X 2, ..., based on the X n, Bayes' theorem Therefore, it can be expressed by the following formula (1).
- ⁇ MAP in the above equation (2) is used as an estimated value of the processing time of the target figure number in the target process.
- step S14 the process time estimation process described above is executed with all processes as target processes.
- step S14 after the processing time of the target figure number in each target process is estimated as described above, the process proceeds to step S16, and the bottleneck estimation unit 40 estimates the bottleneck process in each surface mounting line 20.
- the bottleneck estimation unit 40 estimates a process having the longest processing time in each surface mounting line 20 as a bottleneck process. For example, as shown in FIG. 8A, there are six mounter devices (mounter 1 to mounter 6) in the mounter line, and the processing time (predicted processing time) of each mounter device determined in the production plan. ) Is the time as shown in FIG. In this case, when the bottleneck process is estimated based on the processing time of FIG. 8B, the mounter 4 becomes the bottleneck process.
- step S18 the line production completion time estimation unit 42 executes processing for estimating the production completion time of each line.
- step S18 the process according to the flowchart of FIG. 9 is executed.
- step S50 the line production completion time estimation unit 42 acquires the current time T now .
- step S52 the line production completion time estimation unit 42 selects one surface mounting line 20.
- step S54 the line production completion time estimation unit 42 obtains the processing time (elapsed time) t B of the substrate being processed in the bottleneck process.
- the elapsed time t B can be obtained from the following equation (3).
- t B T now -production start time (3)
- step S56 the line production completion time estimation unit 42 obtains the remaining time Z of the drawing number i being manufactured.
- m is the number of substrates that have not yet been started in the bottleneck process of drawing number i being manufactured
- the remaining time Z can be obtained from the following equation (4).
- Z
- ⁇ B in the above equation (4) is the ⁇ MAP calculated in step S14.
- the number m is the difference between the number of substrates stored in the first substrate information table 152A in FIG. 5 and the number of processed substrates that can be counted from the production status table 154B for each substrate in FIG.
- step S60 the line production completion time estimation unit 42 determines whether or not the next figure number exists on the same surface mounting line 20 as the figure number i. If the determination in step S60 is affirmative, the process proceeds to step S62, and the line production completion time estimation unit 42 sets the figure number next to the figure number i as the figure number i.
- the line production completion time estimation unit 42 refers to the second board information table 152C in FIG. 5 and identifies the next figure number.
- step S64 the line production completion time estimation unit 42 determines whether or not a drawing number of the same type as the drawing number i has been manufactured on the same line.
- a figure number of the same type as the figure number i can be identified from the second board information table 152C and the first board information table 152A in FIG. Therefore, the line production completion time estimation unit 42 determines whether or not production of the same type of board as the figure number i has been performed in the past on the same line based on the production status table 154A for each figure number. If the determination in step S64 is affirmative, the process proceeds to step S66. On the other hand, if the determination in step S64 is negative, the process proceeds to step S68.
- the line production completion time estimation unit 42 sets the processing time z i of the figure number i to the same type in the past. Calculate from the processing time of the figure number.
- the line production completion time estimation unit 42 divides the production time of the first board information table 152A (01:30 in the above example) by the number of boards (100 boards).
- the processing time z i is obtained from the following equation (5).
- the number of substrates q can be acquired from the field of the number of substrates in the first substrate information table 152A.
- Z i ⁇ B ⁇ q (5)
- step S66 After the process of step S66 is performed as described above, the process proceeds to step S70.
- step S68 After the process of step S68 is performed as described above, the process proceeds to step S70.
- step S60 the processes and determinations in steps S60 to S70 are repeated until the determination in step S60 is denied. If the determination in step S60 is negative, the process proceeds to step S72.
- the production time is the sum of the processing time of the figure number currently being produced and the processing time of one or more figure numbers produced after the figure number being produced. It is demanded as.
- the line production completion time estimating unit 42 calculates on the basis of the estimated value T j of the production completion time to the following equation (7).
- T j T now + Y (7)
- step S74 the line production completion time estimation unit 42 determines whether or not all lines have been selected. If the determination in step S74 is negative, the process returns to step S52, the subsequent processing / determination is executed, and the estimated value of the production completion time of the next surface mounting line 20 is calculated. If the determination in step S74 is affirmed, the entire process in FIG. 9 is terminated, and the process proceeds to step S20 in FIG.
- the production completion times of the plurality of surface mounting lines 20 are calculated using the processing time determined in the production plan, the production completion times t LA and t LB as shown in FIG. , T LC is calculated.
- T LC is calculated.
- the processing time after time t is estimated based on the production results so far. More appropriate times can be estimated as the production completion times t LA ′, t LB ′, and t LC ′.
- the work order determination unit 44 determines the work order of the chocolate stop. Specifically, the work order determination unit 44 prioritizes each process determined from the estimation result of the bottleneck process of each surface mounting line estimated in step S16 and the production completion time of each line estimated in step S18. Based on the ranking, the work order of the chocolate stops is determined.
- the priority order between the lines is given priority over the priority order in the lines.
- the priority order between the lines is the order in which the production completion time is late.
- the device that executes the bottleneck process is ranked first, the previous device is second, the next device is third, and the second device is fourth.
- the second device is determined as the fifth device.
- the priority order in the line is determined as described above because the device that executes the bottleneck process may stop when the device after the bottleneck process stops. Considering the circumstances. If there is a buffer that can store a certain number of substrates between each mounter device, the priority order in the line is the device that executes the bottleneck process, and the previous device.
- the second device, the second previous device, the third device, and the third previous device may be determined as the fourth device.
- the work order determination unit 44 determines a work order of the chocolate stops by arranging a plurality of mounter devices in which the chocolate stops have occurred in the order of priority (the order of the numerical values of the ranks is small).
- step S22 the work order display unit 46 transmits the information on the work order of the chocolate stop to the worker terminal 60 in order to display the work order of the chocolate stop determined in step S20.
- the work order of the chocolate stops is displayed on the display unit of the worker terminal 60 in the format shown in FIG.
- the operator can perform the operation
- the influence which the stop of the apparatus by chocolate stop work has on the production completion time can be reduced.
- a function as a determination unit that determines and outputs the work priority of the choke stop work is realized, including the work order determination unit 44 and the work order display unit 46.
- each of the surface mounting lines 20 is generated when a plurality of problems occur.
- the figure numbers produced in the above are specified, and the observed values X 1 ... X n required when the specified figure numbers are produced in the past in each device of each surface mounting line 20 are acquired, and production plan information is obtained. based on the
- processing time required for each device on each surface mounting line 20 to produce the identified drawing number is estimated by MAP, and the work priority of each device is determined and output based on the estimated processing time.
- processing time can be estimated accurately based on the observation value and prior distribution of processing time of the same figure number as the figure number in production.
- the bottleneck process of each surface mounting line 20 and the production completion time and production completion time of each surface mounting line 20 are estimated, so that the priority order of a plurality of chocolate stop operations is increased. Can be determined appropriately.
- the chocolate stop occurs once every 30 seconds in the entire factory, and 90 hours are required for one chocolate stop operation, and there are four workers performing the chocolate stop operation. The calculation is left for an average of 70 seconds before the work is started. If the bottleneck process is not properly identified (in the case of FIG. 8B), if the chocolate stop operation is performed at random, the bottleneck process will be left for an average of 70 seconds as with the other processes. Become.
- the chocolate stopping work in the bottleneck process is preferentially chocolate stopped by appropriately determining the order of the chocolate stopping work as in the present embodiment. In this case, if the standing time of the bottleneck process is reduced from 70 seconds to 20 seconds, the stop time of the bottleneck process due to the chocolate stop is reduced by 70%. As a result, the decrease in productivity due to the stoppage of the chocolate is reduced by 70%, so that the delay of the production completion time is suppressed accordingly.
- the identified figure among the apparatuses included in the production line 70 when the production line 70 has the surface mounting line 20 that sequentially executes the work for producing the drawing numbers in a plurality of apparatuses, the identified figure among the apparatuses included in the production line 70.
- the device (bottleneck device) with the longest processing time required to produce the number is determined as the device with the highest work priority in the production line, and given to the processing of the bottleneck device when the device is stopped
- the second and subsequent work priorities are determined in order from the device having the greatest influence. Thereby, it becomes possible to determine appropriately the priority order of the choke stop work in each apparatus so that the production completion time in the surface mounting line 20 becomes early.
- the work order determination unit 44 determines the apparatus (bottleneck apparatus) with the longest processing time required to produce the identified figure number as the apparatus with the highest work priority, and the bottleneck apparatus
- the second and subsequent work priorities are determined in the order of the previous device, the next device, the second device, the second device, ... n devices, and n devices. .
- the production completion time of each of the plurality of surface mounting lines 20 is estimated based on the estimated processing time, and the estimated production completion is completed.
- the work priority is determined from the devices included in the surface mounting line 20 whose time is later. Thereby, when there are a plurality of surface mounting lines 20, it is possible to determine the work priority so that the production completion time is advanced.
- the said embodiment demonstrated the case where the production line 70 had the several surface mounting line 20, it is not restricted to this,
- the production line 70 may have only one surface mounting line 20 Good. Also in this case, it is possible to improve the production efficiency of the production line 70 by specifying the bottleneck device based on the estimated processing time and determining the work priority.
- steps S14 to S18 are executed when a plurality of chocolate stops occur simultaneously in FIG. 7 (S12: Yes) is not limited to this.
- the processes in steps S14 to S18 may be executed every predetermined time.
- steps S20 and S22 may be executed based on the latest estimation results obtained in steps S14 to S18 when a plurality of chocolate stops occur simultaneously.
- FIGS. 7 and 9 the case where the processing of FIGS. 7 and 9 is executed by one server 10 has been described.
- the present invention is not limited to this.
- a plurality of servers may be provided, and a process related to production planning, a process for determining a chocolate stop work order, and a process for managing production may be assigned to each server.
- the server 10 may be in an on-premises form managed by a company or the like that owns the production line 70 as in the above embodiment (FIG. 1), or in the cloud as in the production system 200 shown in FIG. It may be in the form of a server.
- the cloud server 110 of FIG. 12 acquires and processes data transmitted from the production line 70 in the factory 150 via the network 180, and provides the processing result to the worker terminal 60.
- the country where the cloud server 110 and the factory 150 are located may be different.
- the above processing functions can be realized by a computer.
- a program describing the processing contents of the functions that the processing apparatus should have is provided.
- the program describing the processing contents can be recorded on a computer-readable recording medium (except for a carrier wave).
- the program When the program is distributed, for example, it is sold in the form of a portable recording medium such as a DVD (Digital Versatile Disc) or CD-ROM (Compact Disc Read Only Memory) on which the program is recorded. It is also possible to store the program in a storage device of a server computer and transfer the program from the server computer to another computer via a network.
- a portable recording medium such as a DVD (Digital Versatile Disc) or CD-ROM (Compact Disc Read Only Memory) on which the program is recorded. It is also possible to store the program in a storage device of a server computer and transfer the program from the server computer to another computer via a network.
- the computer that executes the program stores, for example, the program recorded on the portable recording medium or the program transferred from the server computer in its own storage device. Then, the computer reads the program from its own storage device and executes processing according to the program. The computer can also read the program directly from the portable recording medium and execute processing according to the program. Further, each time the program is transferred from the server computer, the computer can sequentially execute processing according to the received program.
- server (work support device) 20 Surface mounting line (line) 38 Processing time estimation unit (acquisition unit, estimation unit) 44 Work order determination unit (part of the determination unit) 46 Work order display part (part of the decision part) 70 Production line (system)
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Abstract
Description
以下、サーバ10の処理について、図7、図9のフローチャートに沿って、その他図面を適宜参照しつつ、詳細に説明する。なお、図9は、図7のステップS18の具体的な処理を示すフローチャートである。本処理の前提として、生産ライン70のチョコ停作業を実行する作業リソース(作業者)の数は1(1人)であるものとする。
tB=Tnow-生産開始時刻 …(3)
Z=|μB-tB|+μB×m …(4)
Zi=μB×q …(5)
zi=μ0×q …(6)
Tj=Tnow+Y …(7)
20 表面実装ライン(ライン)
38 処理時間推定部(取得部、推定部)
44 作業順決定部(決定部の一部)
46 作業順表示部(決定部の一部)
70 生産ライン(システム)
Claims (11)
- 製品を生産する複数の装置を有するシステムにおいて、同時に発生している複数の問題を解消するための作業を支援する作業支援装置であって、
前記複数の問題が発生した時点で前記装置それぞれで生産している製品を前記装置それぞれにおいて過去に生産した際に要した処理時間の実績情報を取得する取得部と、
記憶部に記憶されている事前分布と、取得した処理時間の実績情報とに基づいて、前記装置それぞれにおいて前記製品を生産するのに要する処理時間をMAP推定する推定部と、
推定した前記処理時間に基づいて、前記装置それぞれの作業優先順位を決定し、出力する決定部と、を備える作業支援装置。 - 前記システムが、製品を生産するための作業を複数の装置において順次実行するラインを有する場合には、
前記決定部は、前記ラインに含まれる装置のうち、推定した処理時間が最も長い装置を、前記ラインにおける作業優先順位が第1位の装置として決定するとともに、装置を停止したときに前記第1位の装置の処理に与える影響が大きい装置から順に第2位以降の作業優先順位を決定する、ことを特徴とする請求項1に記載の作業支援装置。 - 前記複数の装置の間には、前記製品を貯留するバッファがない、又は前記製品の貯留数が所定数未満であるバッファが設けられており、
前記決定部は、前記ラインに含まれる装置のうち、推定した処理時間が最も長い装置を、前記ラインにおける作業優先順位が第1位の装置として決定するとともに、前記第1位の装置の1つ前の装置、1つ後ろの装置、2つ前の装置、2つ後ろの装置、…n個前の装置、n個後ろの装置、の順に第2位以降の作業優先順位を決定する、ことを特徴とする請求項2に記載の作業支援装置。 - 前記システムが前記ラインを複数有する場合には、
前記決定部は、推定した前記処理時間を用いて、複数の前記ラインそれぞれの生産計画が完了する時刻を推定し、推定した前記生産計画が完了する時刻が遅いラインに含まれる装置から前記作業優先順位を決定する、ことを特徴とする請求項2又は3に記載の作業支援装置。 - 前記決定部は、複数の前記ラインそれぞれにおいて未だ生産されていない未生産製品の処理時間を、該未生産製品に類似する製品の処理時間の実績情報に基づいて推定し、複数の前記ラインそれぞれの生産計画が完了する時刻を推定することを特徴とする請求項4に記載の作業支援装置。
- 製品を生産する複数の装置を有するシステムにおいて、同時に発生している複数の問題を解消するための作業を支援する作業支援方法であって、
前記複数の問題が発生した時点で前記装置それぞれで生産している製品を前記装置それぞれにおいて過去に生産した際に要した処理時間の実績情報を取得し、
記憶部に記憶されている事前分布と、取得した処理時間の実績情報とに基づいて、前記装置それぞれにおいて前記製品を生産するのに要する処理時間をMAP推定し、
推定した前記処理時間に基づいて、前記装置それぞれの作業優先順位を決定し、出力する、処理をコンピュータが実行する作業支援方法。 - 前記システムが、製品を生産するための作業を複数の装置において順次実行するラインを有する場合には、
前記決定し、出力する処理において、前記ラインに含まれる装置のうち推定した処理時間が最も長い装置を、前記ラインにおける作業優先順位が第1位の装置として決定するとともに、装置を停止したときに前記第1位の装置の処理に与える影響が大きい装置から順に第2位以降の作業優先順位を決定する、ことを特徴とする請求項6に記載の作業支援方法。 - 前記複数の装置の間には、前記製品を貯留するバッファがない、又は前記製品の貯留数が所定数未満であるバッファが設けられており、
前記決定し、出力する処理において、前記ラインに含まれる装置のうち、推定した処理時間が最も長い装置を、前記ラインにおける作業優先順位が第1位の装置として決定するとともに、前記第1位の装置の1つ前の装置、1つ後ろの装置、2つ前の装置、2つ後ろの装置、…n個前の装置、n個後ろの装置、の順に第2位以降の作業優先順位を決定する、ことを特徴とする請求項7に記載の作業支援方法。 - 前記システムが前記ラインを複数有する場合には、
前記決定し、出力する処理において、推定した前記処理時間を用いて、複数の前記ラインそれぞれの生産計画が完了する時刻を推定し、推定した前記生産計画が完了する時刻が遅いラインに含まれる装置から前記作業優先順位を決定する、ことを特徴とする請求項7又は8に記載の作業支援方法。 - 前記決定し、出力する処理において、複数の前記ラインそれぞれにおいて未だ生産されていない未生産製品の処理時間を、該未生産製品に類似する製品の処理時間の実績情報に基づいて推定し、複数の前記ラインそれぞれの生産計画が完了する時刻を推定することを特徴とする請求項9に記載の作業支援方法。
- 製品を生産する複数の装置を有するシステムにおいて、同時に発生している複数の問題を解消するための作業を支援する作業支援プログラムであって、
前記複数の問題が発生した時点で前記装置それぞれで生産している製品を前記装置それぞれにおいて過去に生産した際に要した処理時間の実績情報を取得し、
記憶部に記憶されている事前分布と、取得した処理時間の実績情報とに基づいて、前記装置それぞれにおいて前記製品を生産するのに要する処理時間をMAP推定し、
推定した前記処理時間に基づいて、前記装置それぞれの作業優先順位を決定し、出力する、処理をコンピュータに実行させる作業支援プログラム。
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