WO2022158226A1 - 生産フロア管理システム、作業対策決定方法および作業対策決定プログラム - Google Patents
生産フロア管理システム、作業対策決定方法および作業対策決定プログラム Download PDFInfo
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
- G06Q50/04—Manufacturing
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- G—PHYSICS
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- G05B19/00—Programme-control systems
- 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]
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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
- G05B19/00—Programme-control systems
- 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]
- G05B19/4184—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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- 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
- G05B19/00—Programme-control systems
- 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]
- G05B19/41875—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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- G—PHYSICS
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- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
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Definitions
- Patent Document 1 When a problem occurs in a production device, a technique has been disclosed that outputs work instructions according to the method of coping while updating the method of coping with the problem (for example, Patent Document 1).
- FIG. 1 An embodiment will be described below with reference to FIGS. 1 to 12.
- FIG. 1 An embodiment will be described below with reference to FIGS. 1 to 12.
- the substrate supply device M1, the substrate transfer device M2, the printer M3, the mounting devices M4 and M5, the reflow device M6, and the substrate recovery device M7 are arranged in this order. connected in series. Each device from the substrate supply device M1 to the substrate recovery device M7 is connected to the management device 5 via the communication network 2.
- FIG. 1 the substrate supply device M1, the substrate transfer device M2, the printer M3, the mounting devices M4 and M5, the reflow device M6, and the substrate recovery device M7 are arranged in this order. connected in series.
- Each device from the substrate supply device M1 to the substrate recovery device M7 is connected to the management device 5 via the communication network 2.
- the production floor management system 1 is a computer placed on the production floor.
- the functions of the production floor management system 1 may be provided in the management device 5 .
- the production floor management system 1 may be a computer provided in one housing, or may be divided into two or more housings and implemented by two or more computers.
- the production floor management system 1 may not be arranged on the production floor, and may be a computer such as a server provided outside the production floor. Note that workers are not limited to humans, and include robots, work mechanisms, and automated guided vehicles that perform the above-described work.
- the production floor management system 1 is a system that outputs instructions to workers or production equipment on the production floor according to the state of the production floor.
- the production floor management system 1 includes an acquisition unit 10, a state monitoring unit 20, a countermeasure determination unit 30, a countermeasure mediation unit 40, an instruction output unit 50, an effect determination unit 60, an update unit 70, learning models 23, 24, 33 and 34, Also, a resource database 41 is provided.
- the production floor management system 1 is implemented by a computer including a processor, memory and the like.
- the acquisition unit 10, the state monitoring unit 20, the countermeasure determination unit 30, the countermeasure mediation unit 40, the instruction output unit 50, the effect determination unit 60, and the update unit 70 are implemented by the processor operating according to the program stored in the memory. .
- information indicating the state of production resources may be sensing data from a camera, sensor, or the like, or may be data input by a person.
- the acquisition unit 10 acquires event information that has changed on the production floor. More specifically, the acquisition unit 10 detects when the production apparatus stops, when the feeder, nozzle, parts, or board attached to the production apparatus is replaced, when the worker who performs the work is replaced, or when the operation data of the production apparatus is changed. Acquire information indicating that the
- the first state monitoring unit 21 monitors, within a predetermined period, at least information on production errors occurring in the production equipment, information on the amount of products produced by the production equipment, and quality information on the products produced by the production equipment. A first predetermined condition corresponding to a production index for one is detected.
- FIG. 3 is a diagram showing an example of objects monitored by the state monitoring unit 20 according to the embodiment.
- the production apparatus is assumed to be a mounting apparatus, and the production process is assumed to be a mounting process.
- the countermeasure determination unit 30 updates the priority based on a learning model for updating the priority.
- the second condition may be a data table containing priorities set for each of a plurality of countermeasures instead of the learning model.
- the countermeasure determination unit 30 has a first countermeasure determination unit 31 and a second countermeasure determination unit 32 .
- the first countermeasure determination unit 31 and the second countermeasure determination unit 32 each perform the operation of the countermeasure determination unit 30 described above.
- the first countermeasure determination unit 31 determines the first countermeasure based on the learning model 33 .
- the learning model 33 is a learning model for determining the first countermeasure corresponding to the first state, and specifically, a learning model for updating the priority.
- the learning model 33 is also a second learning model (ie, second condition) associated with a plurality of countermeasures and priorities corresponding to the predetermined state.
- the second countermeasure determination unit 32 determines the second countermeasure based on the learning model 34 .
- the learning model 34 is a learning model for determining a second countermeasure corresponding to the second state, and more specifically, a learning model for updating the priority.
- Learning model 34 is also a second learning model (ie, second condition) associated with a plurality of countermeasures and priorities corresponding to a given state.
- the second countermeasure determined here may be completed by notifying the second countermeasure to a maintenance plan creation device or worker management device provided separately from the production floor management system 1, or the second countermeasure may be completed. 2 It may be completed after receiving the execution result of countermeasures.
- the countermeasure arbitration unit 40 determines the first countermeasure and the second countermeasure based on the problem level set in the first state corresponding to the first countermeasure and the problem level set in the second state corresponding to the second countermeasure. conduct mediation with Also, for example, the countermeasure arbitration unit 40 arbitrates between the first countermeasure and the second countermeasure based on the presence or absence of production resources required for the first countermeasure or the second countermeasure. The presence or absence of production resources is managed by the resource database 41 .
- the instruction output unit 50 outputs the first priority instruction. Specifically, the instruction output unit 50 outputs the first countermeasure or the second countermeasure, which is the first priority instruction, according to the arbitration by the countermeasure arbitration unit 40 . For example, until the effect determination unit 60, which will be described later, determines the effect of the executed first priority instruction, the instruction output unit 50 determines the second priority instruction, which is determined from among the plurality of countermeasures, and has the priority after the first priority instruction. Do not output priority instructions. Further, for example, when the first priority instruction is executed, the effect determination unit 60 changes the state of the production floor after execution of the first priority instruction to the state of the production floor before execution of the first priority instruction.
- the instruction output unit 50 does not output the second priority instruction before execution, which is extracted in relation to the state on the production floor corresponding to the first priority instruction. Further, for example, when the first priority instruction is executed, the effect determination unit 60 changes the state of the production floor after execution of the first priority instruction to the state of the production floor before execution of the first priority instruction. If it is determined that there is no improvement tendency as described above, the countermeasure determination unit 30 determines the second priority instruction to be executed based on the priority of each of the plurality of countermeasures excluding the first priority instruction, and the instruction output unit 50 outputs the second priority indication.
- the countermeasure determination unit 30 determines the second priority to be executed based on the priority of each of the plurality of countermeasures excluding the first priority instruction. After determining the instruction, the instruction output unit 50 outputs the second priority instruction.
- the instruction output unit 50 may output an instruction to a control unit of a production apparatus or a mobile terminal possessed by a worker, or through a production management apparatus that manages the production apparatus or a worker management apparatus that manages workers. Instructions may be output to production equipment and workers.
- the monitoring of the first state by the first state monitoring unit 21 and the determination of the first countermeasure by the first countermeasure determining unit 31, the monitoring of the second state by the second state monitoring unit 22 and the second countermeasure determining unit 32 The determination of the second countermeasure by is carried out in parallel. For example, process guarantees can be achieved by the OODA loop from both MTBF and MTTR.
- the first state is the production state of the production equipment and the second state is the production resource state
- the present invention is not limited to this.
- the first state may be the production state of the production device
- the second state may be the production state of the production device different from the first state.
- the first state may be the state of the production resource
- the second state may be the state of the production resource different from the first state.
- FIG. 4 shows an example in which the MTBF cycle and the MTTR cycle are performed in parallel, a plurality of MTBF cycles may be performed in parallel, or a plurality of MTTR cycles may be performed in parallel.
- the countermeasure arbitration unit 40 may prioritize the first countermeasure over the second countermeasure.
- the degree of problem which will be described below, the operation of the production equipment can be maintained by giving priority to the first countermeasure.
- the phrase "there is no difference in the degree of problem" as used herein includes that the degree of problem is the same and that the difference in the degree of problem is within a predetermined difference.
- the state monitoring unit 20 reads the learning model (step S12). Specifically, the first state monitoring unit 21 reads the learning model 23 and the second state monitoring unit 22 reads the learning model 24 .
- productivity is increased and quality is decreased.
- the learning policy is set to emphasize quality, learning is performed so that the detection threshold corresponding to productivity is loosened (decrease in productivity is less likely to be detected) based on the above effect. . Thereby, a detection threshold that balances productivity and quality is learned.
- the state monitoring unit 20 determines whether or not a problem has been detected in the first predetermined state or the second predetermined state (step S13). For example, the first state monitoring unit 21 determines whether or not it is detected that the productivity is declining, the quality is declining, or the number of defective products is increasing. For example, the second state monitoring unit 22 determines whether or not it has detected that the production equipment is deteriorating, that the equipment elements are deteriorating, or that there is an error in the worker's work.
- FIG. 6 is a flow chart showing an example of the operation of the countermeasure determination unit 30 according to the embodiment.
- FIG. 6 shows the processing of policy determination (Orient) in the OODA loop.
- the countermeasure determining unit 30 analyzes the production resources (for example, production resources that can be the cause) for the problem detected by the state monitoring unit 20 (step S21). For example, when the first state monitoring unit 21 detects a problem that productivity is declining in the mounting process of the mounting apparatus, the production resources that can cause the problem are substrates, parts, workers, heads, nozzles, and so on. and feeders (see FIG. 3). Also, for example, when the second state monitoring unit 22 detects a problem of nozzle deterioration, it analyzes that the nozzle is the production resource that can cause the problem.
- the production resources for example, production resources that can be the cause the problem.
- the learning model 34 is a learning model for determining the second countermeasure corresponding to the state of production resources, and specifically, a learning model for updating the priority for determining the priority of the second countermeasure. is.
- the learning model 34 is trained to output countermeasures for the detected problem as candidates by inputting the detected problem. If multiple candidates are output for the detected problem, multiple countermeasures are extracted corresponding to the multiple candidates. A learning method of the learning model 34 will be described later.
- acquisition of monitoring data is repeated at predetermined time intervals, and various problems can be detected. For example, one problem may be detected before the remedy for another problem is completed. For example, multiple problems with a first predetermined condition (e.g., productivity, quality, or work errors, etc.) may be detected. In this way, each time a problem is detected, a countermeasure candidate list for that problem is created, and the countermeasure with the highest priority for each countermeasure candidate list is added to the priority countermeasure list.
- FIG. 8 shows an example of the priority countermeasure list.
- the presence or absence of each production resource specifically, whether each production resource is currently taking some measures, or whether each production resource is currently taking any measures It is managed whether or not In FIG. 10, the presence or absence of production resources is indicated by locking on and off.
- the resource management table shown in FIG. 10 manages the presence or absence of heads, nozzles, feeders, and workers A and B as production resources.
- the head and feeder are currently under some kind of countermeasure and the lock is on.
- the nozzle is currently unlocked as no countermeasures are being taken. Workers A and B are currently unlocked because they are not taking any countermeasures.
- the lock referred to here may include either real space or virtual space, or both.
- the effect determination unit 60 acquires monitoring data (step S42). Specifically, the effect determination unit 60 acquires monitoring data regarding the production status of production equipment or monitoring data regarding the status of production resources.
- the reason why the effect determination unit 60 acquires the monitoring data is to confirm the change in the state on the production floor due to the execution of the instruction according to the countermeasure, that is, to determine the effect of the instruction according to the executed countermeasure. is.
- the effect determination unit 60 acquires monitoring data about the result of the mounting process regarding suction. That is, the effect determination unit 60 monitors the tendency of the error information related to the monitored nozzle as monitoring data.
- the effect determination unit 60 acquires monitoring data about the state of the feeder.
- the updating unit 70 updates the learning model 33 or 34 based on the determined effect (step S44). For example, in the case of Concrete Example 1, when the problem is no longer detected, the updating unit 70 determines that the suction position teaching was effective against the problem, and the priority of the suction position teaching is increased.
- the learning model 33 is updated as follows. For example, in the case of Specific Example 2, when the problem is no longer detected, the updating unit 70 determines that cleaning was effective against the problem, and sets the learning model so that cleaning has a higher priority. Update 34.
- the instruction output unit 50 When it is determined that the suction error rate after execution of the suction position teaching instruction is improved by a predetermined amount or more, the instruction output unit 50 outputs the extracted suction error rate corresponding to the suction position teaching instruction. , means that the second priority instruction (instruction of feeder replacement or nozzle replacement) before execution is not output.
- the effect determination unit 60 may also determine whether a problem presented in the prioritized countermeasure list continues in addition to the problem for which countermeasures have been taken. The effect determination unit 60 may delete the prioritized countermeasure list for problems for which no problems are detected other than the problems for which countermeasures have been taken. Some of the problems detected are relevant and efficient countermeasures can be taken against such problems.
- the effect determination unit 60 registers the highest-priority measure candidate in the created measure candidate list in the priority measure list as a measure against the detected problem (step S53). For example, when the countermeasure candidate list shown in FIG. 12 is created, a countermeasure of exchanging nozzles is registered in the priority countermeasure list for the problem of deterioration of the suction error rate. In other words, an instruction to replace the nozzle can be output in response to the problem that the suction error rate continues to deteriorate even after the suction position teaching is performed.
- the countermeasure determination unit 30 selects a plurality of countermeasures (feeder exchange instruction and nozzle exchange instruction) excluding the first priority instruction (suction position teaching). ), the second priority instruction (nozzle replacement) to be executed is determined, and the instruction output unit 50 outputs the nozzle replacement instruction. This is because, after the time-out, an instruction to replace the nozzle with the highest priority among the plurality of countermeasures excluding the suction position teaching is output.
- step S13 after a problem is detected by the state monitoring unit 20 and a high-priority countermeasure is registered in the priority countermeasure list from the countermeasure candidate list for the problem, the registered countermeasure may have a low priority.
- the registered countermeasures may not be executed easily because the production resources for the registered countermeasures have already been locked.
- the previously executed countermeasures for other problems may solve the problems corresponding to the unexecuted countermeasures.
- it may be deleted from the priority countermeasure list and the countermeasure candidate list may also be deleted.
- the first state is the production state of the production equipment and the second state is the production resource state, but the present invention is not limited to this.
- the first state and the second state are not particularly limited as long as they are different states on the production floor.
- the production floor management system 1 includes the acquisition unit 10, the state monitoring unit 20, the countermeasure determination unit 30, the countermeasure mediation unit 40, the instruction output unit 50, the effect determination unit 60, and the update unit 70. , some of which may be included in the production equipment.
- a production device may include the acquisition unit 10 , the state monitoring unit 20 , and the countermeasure determination unit 30 .
- instructions according to countermeasures may consist of multiple instructions.
- instructions corresponding to countermeasures may be output to a plurality of production apparatuses or mobile terminals possessed by a plurality of workers.
- the present disclosure can be implemented not only as the production floor management system 1, but also as a work countermeasure determination method including steps (processes) performed by each component constituting the production floor management system 1.
- FIG. 13 is a flow chart showing an example of a work countermeasure determination method according to another embodiment.
- the work countermeasure determination method is a work countermeasure determination method in a production floor management system that manages the state of a production floor equipped with production equipment that produces products.
- a predetermined state is detected based on a first condition for detecting a predetermined state among the above states (step S1), and a countermeasure to be executed is determined based on a second condition for determining a countermeasure corresponding to the predetermined state. is determined (step S2), the effect of the executed countermeasure is determined based on the states before and after the determined countermeasure is executed (step S3), and the first condition and the second condition are determined based on the determined effect 2 conditions are updated (step S4).
- the steps in the work countermeasure determination method may be executed by a computer (computer system).
- the present disclosure can be realized as a program for causing a computer to execute the steps included in the work countermeasure determination method.
- the present disclosure can be implemented as a non-temporary computer-readable recording medium such as a CD-ROM recording the program.
- each step is executed by executing the program using hardware resources such as the CPU, memory, and input/output circuits of the computer. . That is, each step is executed by the CPU acquiring data from a memory, an input/output circuit, or the like, performing an operation, or outputting the operation result to the memory, an input/output circuit, or the like.
- the integrated circuit is not limited to an LSI, and may be realized by a dedicated circuit or a general-purpose processor.
- a programmable FPGA (Field Programmable Gate Array) or a reconfigurable processor capable of reconfiguring connections and settings of circuit cells inside the LSI may be used.
- the present disclosure can be used, for example, for managing production floors.
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Abstract
Description
このように、生産装置の稼働情報、生産フロアで作業する作業者情報、および生産物に用いられる材料情報を分析することで、効果的に最適な作業指示を出力することができる。
以下、図1から図12を用いて実施の形態について説明する。
以上、本開示の生産フロア管理システム1について、実施の形態に基づいて説明したが、本開示は、上記実施の形態に限定されるものではない。本開示の趣旨を逸脱しない限り、当業者が思いつく各種変形を本実施の形態に施したもの、および、異なる実施の形態における構成要素を組み合わせて構築される形態も、本開示の範囲内に含まれる。
2 通信ネットワーク
4 実装ライン
5 管理装置
10 取得部
20 状態監視部
21 第1状態監視部
22 第2状態監視部
23、24、33、34 学習モデル
30 対策決定部
31 第1対策決定部
32 第2対策決定部
40 対策調停部
41 リソースデータベース
50 指示出力部
60 効果判定部
70 更新部
M1 基板供給装置
M2 基板受渡装置
M3 印刷装置
M4、M5 実装装置
M6 リフロー装置
M7 基板回収装置
Claims (7)
- 生産物を生産する生産装置を備える生産フロアにおける状態を管理する生産フロア管理システムであって、
前記状態を監視して、前記状態のうち所定状態を検出するための第1条件に基づいて、前記所定状態を検出する状態監視部と、
前記所定状態に対応した対策を決定するための第2条件に基づいて、実行する前記対策を決定する対策決定部と、
決定された前記対策が実行された前後の前記状態に基づいて、実行された前記対策の効果を判定する効果判定部と、
判定された前記効果に基づいて、前記第1条件および前記第2条件を更新する更新部と、を備える
生産フロア管理システム。 - 前記対策は複数あり、
前記第2条件は、前記複数の対策毎に設定される優先度を含み、
前記対策決定部は、前記所定状態に対応して抽出される前記複数の対策のそれぞれの前記優先度に基づいて、前記複数の対策のうちから出力する前記対策を決定する
請求項1に記載の生産フロア管理システム。 - 前記第1条件は、前記所定状態に対応した検出閾値に関連付けられた第1学習モデルであり、
前記第2条件は、前記所定状態に対応した前記複数の対策および前記優先度に関連付けられた第2学習モデルである
請求項2に記載の生産フロア管理システム。 - 前記所定状態に対応した検出閾値は、前記生産装置が備えるノズルの流量に対応した検出閾値、前記生産装置が備えるフィーダのテープ停止位置のずれに対応した検出閾値、ノズルが吸着した部品の吸着位置ずれに対応した検出閾値、または基板の搬送位置ずれに対応した検出閾値のいずれかひとつを含む
請求項3に記載の生産フロア管理システム。 - 前記対策決定部は、前記所定状態に対応した前記対策を決定するために、前記生産フロアで取得される前記生産装置の稼働情報、前記生産フロアで作業する作業者情報、および前記生産物に用いられる材料情報を分析する
請求項1から4のいずれかひとつに記載の生産フロア管理システム。 - 生産物を生産する生産装置を備える生産フロアにおける状態を管理する生産フロア管理システムにおける作業対策決定方法であって、
前記状態を監視して、前記状態のうち所定状態を検出するための第1条件に基づいて、前記所定状態を検出し、
前記所定状態に対応した対策を決定するための第2条件に基づいて、実行する前記対策を決定し、
決定された前記対策が実行された前後の前記状態に基づいて、実行された前記対策の効果を判定し、
判定された前記効果に基づいて、前記第1条件および前記第2条件を更新することを含む
作業対策決定方法。 - 請求項6に記載の作業対策決定方法をコンピュータにより実行させる作業対策決定プログラム。
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JPH10283028A (ja) * | 1997-04-07 | 1998-10-23 | Toyota Motor Corp | 設備情報伝達装置 |
JP2004005602A (ja) * | 2003-04-21 | 2004-01-08 | Matsushita Electric Ind Co Ltd | 実装基板生産システムおよびメンテナンス指示システム |
JP2012145997A (ja) * | 2011-01-07 | 2012-08-02 | Fuji Mach Mfg Co Ltd | 生産システム |
JP2013041448A (ja) * | 2011-08-17 | 2013-02-28 | Hitachi Ltd | 異常検知・診断方法、および異常検知・診断システム |
WO2018142604A1 (ja) * | 2017-02-06 | 2018-08-09 | 株式会社Fuji | 作業管理装置 |
JP2020177547A (ja) * | 2019-04-22 | 2020-10-29 | 株式会社ジェイテクト | 作業支援システム |
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JPH10283028A (ja) * | 1997-04-07 | 1998-10-23 | Toyota Motor Corp | 設備情報伝達装置 |
JP2004005602A (ja) * | 2003-04-21 | 2004-01-08 | Matsushita Electric Ind Co Ltd | 実装基板生産システムおよびメンテナンス指示システム |
JP2012145997A (ja) * | 2011-01-07 | 2012-08-02 | Fuji Mach Mfg Co Ltd | 生産システム |
JP2013041448A (ja) * | 2011-08-17 | 2013-02-28 | Hitachi Ltd | 異常検知・診断方法、および異常検知・診断システム |
WO2018142604A1 (ja) * | 2017-02-06 | 2018-08-09 | 株式会社Fuji | 作業管理装置 |
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