Substrate production simulation method

Abstract

In a substrate production simulation method, a product substrate on which component installation is completed using a substrate production line is simulated. The substrate production line includes an installation line formed by arranging a plurality of component installation machines, and the component installation machines install components supplied from a component supply device on the substrate. The method includes steps (a) to (c). In step (a), the simulation is performed on the premise that the substrate production line is provided with and / or recovered by the component supply device without stagnation, and a first result is obtained. In step (b), the simulation is performed on the premise that the substrate production line is provided with and / or recovered by automated equipment and / or operators, and a second result is obtained. In step (c), the production delay of the second result relative to the first result and the parameters of the second result that may be factors of production delay are output on the same screen.

Description

Technical Field

[0001] In this specification, a substrate production simulation method is disclosed. Background Art

[0002] In the past, as a production simulation method, the method disclosed in Patent Document 1 is known. In the method of Patent Document 1, a computer simulation is used to calculate the load caused by the layout of multiple processing devices in the production area, the movement of multiple transport units, and the operator's staffing. In this simulation calculation, the operator's load rate, throughput, device operation rate, etc. are calculated. According to this method, in the formulation of the layout, a design that takes into account the number of operators and the configuration can be performed. In addition, as a method for managing production processes, the method disclosed in Patent Document 2 is known. In the method of Patent Document 2, when the start of the object operation is detected, before the end of the object operation is detected, based on the object operation information reflecting the production schedule information and the actual workload determined based on the operation performance detected for the object operation, it is determined whether the object operation is delayed.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2005-100092

[0006] Patent Document 2: Japanese Patent Application Publication No. 2020-13388 Summary of the invention

[0007] Problems to be solved by the invention

[0008] However, in the method of Patent Document 1, although the operator's load factor, throughput, device operation rate, etc. are calculated, the processing delay caused by the operator's work cannot be grasped. On the other hand, the method of Patent Document 2 is a method for determining the delay of actual work relative to the production plan, and is not a method for simulating the delay of processing based on the operator's work relative to the production plan. Therefore, it is impossible to infer the factors of production delay.

[0009] The present disclosure has been made to solve the above-mentioned problems, and its main purpose is to easily estimate the factors causing production delay in a substrate production simulation method.

[0010] Technical solutions to solve problems

[0011] The substrate production simulation method of the present invention simulates a product substrate on which component installation is completed by using a substrate production line, wherein the substrate production line includes an installation line formed by arranging a plurality of component installation machines along the conveying direction of the substrate, and the component installation machines install the components supplied from a component supply device onto the substrate, wherein the substrate production simulation method includes the following steps: (a) simulating the production of a plurality of product substrates by the substrate production line on the premise that the component supply device is provided and recovered to the substrate production line without stopping, thereby obtaining a first result; (b) simulating the production of a plurality of product substrates by the substrate production line on the premise that the component supply device is provided and / or recovered to the substrate production line by automated equipment and / or an operator, thereby obtaining a second result; and (c) outputting a production delay association display and a parameter association display on the same screen, wherein the production delay association display associates the production delay of the second result relative to the first result with the product substrate, and the parameter association display associates the parameters contained in the second result that may become factors of the production delay with the product substrate.

[0012] In the substrate production simulation method, the first result is the result of simulating the production of multiple product substrates by the substrate production line on the premise that the component supply device of the substrate production line is provided and recovered without stagnation. The second result is the result of simulating the production of multiple product substrates by the substrate production line on the premise that the component supply device of the substrate production line is provided and / or recovered by the automation equipment and / or the operator. Then, a production delay association display that associates the production delay of the second result with the product substrate relative to the first result and a parameter association display that associates the parameters that may become the factors of production delay contained in the second result with the product substrate are output on the same screen. Therefore, by observing the output screen, the factors of production delay can be easily inferred based on the time point when the production delay occurs and the changes in the parameter association display before and after it.

[0013] Furthermore, in step (c), when the production delay or the parameter that may cause the production delay is displayed in association with the product substrate, it can be displayed in association with the timing of the operation of providing and / or recovering the component supply device of the substrate production line, or it can be displayed in association with the operation interval of providing and / or recovering the component supply device of the substrate production line. Such operation timing and operation interval are determined in association with the product substrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 FIG. 1 is a diagram schematically showing the structure of the substrate production layer F. FIG.

[0015] Figure 2 It is a perspective view schematically showing the substrate production line 10 .

[0016] Figure 3 It is a perspective view schematically showing the component mounting machine 20 .

[0017] Figure 4 It is a block diagram showing a configuration related to control of the substrate production line 10 .

[0018] Figure 5 is a flow chart of the first simulation.

[0019] Figure 6 is a graph showing the results of the first simulation.

[0020] Figure 7 Flowchart of the second simulation.

[0021] Figure 8 This is an explanatory diagram showing a state where graphs showing the results of the first simulation and the second simulation are displayed on the same screen.

[0022] Fig. 9 is a flow chart of the simulation results display routine.

[0023] Fig.10 This is an example of a graph showing the load factor and production delay of the job in each period.

[0024] Fig.11 This is an example of a graph showing the assembly line operating rate and production delay for each period.

[0025] Fig.12 This is an example of a graph showing the load distribution of operators and production delays in each period.

[0026] Fig.13 This is an example of a graph showing the load factor and production delay of the job in each period.

[0027] Fig.14 This is an example of a graph showing the assembly line operating rate and production delay for each period.

[0028] Fig.15 This is an example of a graph showing the load distribution of operators and production delays in each period. DETAILED DESCRIPTION

[0029] Next, a mode for implementing the substrate production simulation method of the present disclosure will be described with reference to the drawings. Figure 1 2 is a schematic structural diagram showing the substrate production layer F. Figure 2 is a perspective view schematically showing a substrate production line 10. Figure 32 is a perspective view schematically showing a component mounting machine 20. Figure 4 1 is a block diagram showing a structure related to the control of the substrate production line 10. In addition, in the present embodiment, the left-right direction (X axis), the front-back direction (Y axis), and the up-down direction (Z axis) are as shown in FIG. Figure 2 as well as Figure 3 shown.

[0030] like Figure 1 As shown, the substrate production layer F has a first area A1 and a second area A2. The first area A1 is an area where the production process is implemented. In the first area A1, there is a substrate production line 10 that produces a product (product substrate) in which a plurality of components are mounted on a substrate and soldered. The second area A2 is an area where the logic process is implemented. In the second area A2, there are a component storage warehouse 18, a feeder placement area (not shown), etc. The operator W basically implements the logic process in the second area A2.

[0031] The production process is a process of producing a product (product substrate) on which a plurality of components are mounted and soldered using the substrate production line 10 .

[0032] The logical process includes picking, equipment, transportation (supply), transportation (recovery), and aftercare. Picking is the operation of taking out the tape reel holding the components required for the production operation from the component storage warehouse 18. Equipment is the operation of setting the tape reel on the feeder. Transportation (supply) is the operation of transporting the feeder after equipment is completed from the second area A2 to the substrate production line 10 in the first area A1. Transportation (recovery) is the operation of recovering the feeder that has been used in the production operation and the feeder that has become empty of components and transporting it from the substrate production line 10 in the first area A1 to the second area A2. Aftercare is the following operation: removing the tape reel that has become empty of components from the feeder and discarding it, or reusing the feeder that has components that can be used in the subsequent production operation, or removing the tape reel that holds components that cannot be used in the subsequent production operation from the feeder and returning it to the component storage warehouse 18. The logical process is not only performed by the operator W, but sometimes also by automated equipment. As automated equipment, there are automatic warehouses, unmanned guided vehicles (AGV (Automated Guided Vehicle) 100), etc. The automatic warehouse is used as a component storage warehouse 18, and automatically takes out required components. The AGV 100 is a vehicle that automatically transports feeders, etc., and travels between the first area A1 and the second area A2.

[0033] like Figure 2As shown, the substrate production line 10 includes a printing device 11, a printing inspection device 12, a mounting line 13, a visual inspection device 14, a reflow soldering furnace 15, a feeder storage 60, and a management device 80. These constitute the substrate production line 10 by being arranged in a row in the conveying direction (X direction) of the substrate. The printing device 11 is a device for printing solder on the substrate. The printing inspection device 12 is a device for inspecting the state of the solder printed by the printing device 11. The mounting line 13 is formed by arranging a plurality of component mounting machines 20 along the conveying direction of the substrate. The component mounting machine 20 is a device for taking out the components supplied from the feeder 30 and mounting them on the substrate. The visual inspection device 14 is a device for inspecting the mounting state of the components mounted by the component mounting machine 20. The reflow soldering furnace 15 heats the substrate on which the plurality of components are mounted to melt the solder on the substrate to perform solder bonding. The substrate unloaded from the reflow soldering furnace 15 is a product (product substrate) on which the plurality of components are mounted and soldered. The feeder storage 60 is assembled in the substrate production line 10, and stores the feeders 30 to be used and the used feeders 30 in each component mounting machine 20. The management device 80 manages the entire substrate production line 10. The substrate production line 10 is further provided with a loader 50. The loader 50 can move along the X-axis rail 16, and can automatically replace the feeder 30 between the component mounting machine 20 and the feeder storage 60.

[0034] like Figure 3 As shown, the component mounting machine 20 includes: a substrate conveying device 21, which conveys the substrate in the X direction; a head 22, which has a suction nozzle for sucking the components supplied by the feeder 30; a head moving mechanism 23, which moves the head 22 in the XY direction; and a touch panel display 24 (refer to Figure 2 ) to perform touch input and screen output. The component mounting machine 20 also includes a marking camera 25, a parts camera 26, a nozzle station 27, etc. The marking camera 25 photographs the reference mark marked on the substrate from above in order to detect the position of the substrate. The parts camera 26 photographs the components adsorbed by the nozzle of the head 22 from below in order to detect adsorption errors and adsorption deviations. The nozzle station 27 accommodates a variety of nozzles that can be replaced according to the type of components adsorbed. In addition, the component mounting machine 20 includes a mounting control device 28 composed of a well-known CPU, ROM, RAM, etc. (refer to Figure 4). The mounting control device 28 controls the entire component mounting machine 20. The mounting control device 28 can input and output signals with the substrate conveying device 21, the head 22, the head moving mechanism 23, the touch panel display 24, the marking camera 25, the parts camera 26, etc. In addition, the component mounting machine 20 has two upper and lower areas in the front where the feeder 30 can be installed. The upper area is the supply area 20A where the feeder 30 can supply components, and the lower area is the storage area 20B where the feeder 30 can be stored. Feeder tables 40 that are formed in an L shape when viewed from the side are provided in the supply area 20A and the storage area 20B. A plurality of feeders 30 are installed on each feeder table 40.

[0035] The feeder 30 is a kind of component supply device, such as Figure 3 As shown in FIG. 1 , the tape feeder 30 is configured to feed a tape containing components at a predetermined pitch. The feeder 30 includes a tape reel 32 on which a tape is wound, a tape feed mechanism 33 for feeding the tape from the tape reel 32, and a feeder control device 34 (see FIG. 1 ). Figure 4 ). In addition, the feeder table 40 has a plurality of slots 42 arranged in the X direction at intervals that allow the feeder 30 to be inserted. When the feeder 30 is inserted into the slot 42 of the feeder table 40, the connector (not shown) of the feeder 30 is connected to the connector 45 of the feeder table 40. Thus, the feeder control device 34 can communicate with the control unit (installation control device 28, management device 80, etc.) of the installation destination of the feeder 30. The feeder control device 34 uses the belt feeding mechanism 33 to deliver the components contained in the belt to a predetermined component supply position. When the components at the component supply position are sucked by the suction nozzle of the head 22, the belt feeding mechanism 33 is used again to deliver the components contained in the belt to a predetermined component supply position.

[0036] like Figure 2 As shown, the loader 50 can move along the X-axis rail 16 provided on the front surfaces of the plurality of component mounting machines 20 and the front surface of the feeder storage 60 in parallel with the conveying direction (X direction) of the substrate. Figure 3 as well as Figure 4 As shown, the loader 50 includes a loader moving mechanism 51 and a feeder transfer mechanism 53. The loader moving mechanism 51 moves the loader 50 along the X-axis rail 16. The feeder transfer mechanism 53 installs the feeder 30 from the loader 50 to the component mounting machine 20 or the feeder storage 60, removes the feeder 30 from the component mounting machine 20 or the feeder storage 60 and stores it in the loader 50, or moves the feeder 30 between the upper transfer area 50A and the lower transfer area 50B. Figure 4As shown, the loader 50 includes an encoder 55 and a loader control device 57. The encoder 55 detects the moving position of the loader 50 in the X direction. The loader control device 57 is composed of a well-known CPU, ROM, RAM, etc. The loader control device 57 inputs the detection signal from the encoder 55 and outputs a drive signal to the loader moving mechanism 51 and the feeder transfer mechanism 53.

[0037] The feeder storage 60 has a feeder stage 40 having the same structure as the feeder stage 40 provided in the component mounting machine 20 in order to accommodate the plurality of feeders 30 .

[0038] AGV100 is one of the automated equipments that undertakes the logic process (especially transportation). AGV100 moves between the feeder storage warehouse 60 in the first area A1 and the component storage warehouse 18 in the second area A2, while supplying the feeder 30 loaded with components required for production to the feeder storage warehouse 60 or collecting the used feeder 30 from the feeder storage warehouse 60. Figure 4 As shown, the AGV 100 includes an AGV moving mechanism 101 and a feeder transfer mechanism 103. The AGV moving mechanism 101 is a mechanism for driving the AGV 100 along a predetermined driving track, and includes a motor and a steering device for driving. The feeder transfer mechanism 103 is the same device as the feeder transfer mechanism 53 of the loader 50 described above, and can automatically replace the feeder 30 between the feeder storage warehouse 60 and the component storage warehouse 18. In addition, as shown in FIG. Figure 4 As shown, the AGV 100 includes a position sensor 105 and an AGV control device 107. The position sensor 105 detects the travel position of the AGV 100. The AGV control device 107 is composed of a well-known CPU, ROM, RAM, etc. The AGV control device 107 inputs a detection signal from the position sensor 105 and outputs a drive signal to the AGV moving mechanism 101 and the feeder transfer mechanism 103.

[0039] like Figure 4As shown, the management device 80 is composed of a well-known CPU 81, ROM 82, RAM 83, memory (HDD or SSD) 84, etc., and is connected to an input device 85 such as a keyboard and a mouse, and a display 86 such as an LCD. The management device 80 is connected to the installation control device 28, the loader control device 57, and the AGV control device 107 so as to be able to communicate bidirectionally. The management device 80 receives information related to the installation status of the component mounting machine 20 from the installation control device 28, or receives information related to the driving status of the loader 50 from the loader control device 57, or receives information related to the driving status of the AGV 100 from the AGV control device 107. The management device 80 sends a command signal related to installation to the installation control device 28, or sends a command signal related to the loader 50 to the loader control device 57, or sends a command signal related to the AGV 100 to the AGV control device 107. The management device 80 is connected to the feeder control device 34 of the feeder 30 stored in the feeder storage 60 so as to be able to communicate, and can obtain information of the stored feeder 30. The management device 80 stores the production plan in the memory 84. The production plan includes production information, production targets, etc. The production information includes information related to the components required when making the product substrate, information related to the target number of blocks for making the product substrate, etc. The production plan plans the production of multiple product substrates. Therefore, the production information is stored for each type of product substrate. The production target includes the target production time required to execute the production plan, etc.

[0040] Next, a description will be given of a first simulation performed by the management device 80. The first simulation is a simulation performed on the premise that the feeder 30 is supplied to and recovered from the mounting line 13 without stagnation. Figure 5 : is a flowchart of the first simulation. In the first simulation, when a plurality of product substrates are continuously produced, the production operation assigned to each component mounting machine 20 is optimized in a manner that maximizes the production efficiency in the mounting line 13, and the number of component mounting machines 20 constituting the mounting line 13 is set in a manner that meets the production target. The production operation is an operation that determines which feeder 30 is to be set on the feeder table 40 and in what order, and which component type components are to be mounted toward the substrate in what order, etc. for each component mounting machine 20.

[0041] When the first simulation starts, the CPU 81 of the management device 80 reads the current production plan from the memory 84 (S110). Next, the CPU 81 sets a predetermined initial value (for example, 4) for the number of component mounting machines constituting the mounting line 13 (S120). Next, the CPU 81 performs optimization processing on all component mounting machines 20 constituting the mounting line 13, and generates a production operation group (including the production operations of all component mounting machines 20) (S130). Here, it is assumed that a plurality of product substrates are produced in sequence according to their respective target numbers of blocks. Therefore, a production operation group is generated for each type of product substrate. Next, the CPU 81 calculates the scheduled production time required to execute the current production plan (S140). When calculating the scheduled production time, if the CPU 81 needs to replace the feeder 30 based on the loader 50 when starting to produce the next product substrate after producing a certain product substrate of the target number of blocks, the scheduled production time is also calculated taking into account the operation time of the loader 50. Next, the CPU 81 determines whether the scheduled production time is within the target production time (S150). If the scheduled production time exceeds the target production time, the number of component mounting machines 20 constituting the mounting line 13 is increased by 1 (S160), and the process returns to S130 again. On the other hand, if the scheduled production time is within the target production time in S150, the CPU 81 stores the number of component mounting machines 20 at that time and the optimized production operation group in the memory 84 (S170). Thereafter, the CPU 81 generates a graph showing the number of production blocks of product substrates corresponding to the passage of time based on the result obtained in S170 (refer to Figure 6 ), and save the chart in the memory 84 (S180), and end the simulation.

[0042] Here, the optimization processing of the production operation group in the case of making a certain product substrate is described. The CPU 81 finds the production operation group in which the predetermined processing time (predetermined cycle time) of the production operation in each component mounting machine 20 is within the predetermined allowable range and the production time in the mounting line 13 is the shortest. When generating the production operation, the CPU 81 sets the assembly sequence based on the production plan, assigns the assembly sequence to each component mounting machine 20, sets the installation order of the assigned components for each component mounting machine 20, sets the arrangement of the feeder 30 for each component mounting machine 20, and generates the production operation of all component mounting machines 20. The assembly sequence is set by specifying the component type, assembly position and the type of suction nozzle used (the type of suction nozzle used) according to the assembly sequence. The distribution of the assembly sequence to each component mounting machine 20 is performed in a manner that the number of assembly sequences assigned to each component mounting machine 20 is equal or as equal as possible. The assembly sequence of the components is set so that, for example, when the components are assembled on the substrate, the assembly of the components will not be hindered by the components assembled first. The arrangement of the feeders 30 is set, for example, so that the feeders 30 that supply the largest number of components to be mounted on the substrate in each component mounting machine 20 are closer to the center of the feeder table 40. There are many kinds of assembly timings, allocation of assembly timings, installation order of allocated components, and arrangement of feeders 30, so the number of combinations of production operation groups becomes huge. When calculating the scheduled cycle time of each component mounting machine 20, the CPU 81 calculates the scheduled cycle time based on simulation or data accumulated in the past. From the combination of the huge number of production operation groups, the CPU 81 finds a production operation group whose scheduled cycle time of all component mounting machines 20 is within the predetermined allowable range and whose production time is the shortest.

[0043] Figure 6 is a graph showing the result of the first simulation, and is a graph showing the change in the number of produced product substrates over time when a plurality of types of product substrates are produced. Figure 6 In the graph, there are 21 types of product substrates, namely, T1 to T21. In the graph, there are multiple rightward rising lines, but each line segment represents the process of producing a target number of product substrates of one type. For example, the process until the target number of product substrates of type T1 are produced is shown in Figure 6 The process is represented by the rightward rising line segment on the far left. If the process is completed, the number of substrates is temporarily reset to zero. After that, the process until the target number of product substrates of type T2 are produced is repeated. Figure 6 In the figure, it is represented by the second line segment rising to the right from the left. In addition, the section from the production of the target number of product substrates of type T5 to the start of the production of product substrates of type T6 becomes a line segment falling to the right, but in this section, the feeder 30 replacement operation performed by the loader 50 of the substrate production line 10 is performed.

[0044] Next, the second simulation performed by the management device 80 will be described. Figure 7 1 is a flowchart of the second simulation. The second simulation is a simulation performed on the premise that the automated equipment (AGV100, automatic warehouse, etc.) and the operator W provide and recover the feeder 30 to the assembly line 13, and is performed after the first simulation is completed. The second simulation is implemented, for example, by Plant Simulation made by Siemens.

[0045] Before the second simulation starts, the operator uses the input device 85 to input information required for the second simulation. As the information required for the second simulation, for example, in addition to the number of operators W in charge of the logic process, the types and number of automated equipment, and the production start time, the operation time required for picking, the operation time required for equipment, the time required for transportation, the operation time required for post-processing, etc. are listed. As the operation time required for picking, the time to take out the components from the component storage warehouse 18, the time to move the components from the picking work site to the equipment work site, etc. are listed. As the operation time required for equipment, the time to take out the feeder 30 from the feeder placement, the time to install the reel 32 on the feeder 30, etc. are listed. As the time required for transportation, the transportation time for supplying the feeder 30 from the second area A2 to the substrate production line 10 in the first area A1, the transportation time for recovering the feeder 30 from the substrate production line 10 in the first area A1 and moving it to the second area A2, etc. are listed. Such a transport time can be calculated based on the moving speed and moving distance of the operator W when the operator W is transporting, and can be calculated based on the moving speed and moving distance of the AGV 100 when the AGV 100 is transporting. Examples of the time required for post-processing include the time to remove the reel 32 from the feeder 30 and the time to return the feeder 30 to the feeder placement location. The information input by the operator is stored in the memory 84.

[0046] When the second simulation starts, the CPU 81 of the management device 80 reads the current production plan, the results obtained by the first simulation (the number of component mounting machines 20 included in the mounting line 13 and the production operation group), and the information required for the second simulation from the memory 84 (S210). Next, the CPU 81 calculates the delay caused by the supply and recovery of the feeder 30 by the automation equipment and the operator W to the mounting line 13 (S220). The delay is calculated based on the information read in S210. For example, in the case of the delay obtained by the first simulation, Figure 6In the graph of , the time from the end of the production of the product substrate of type T8 to the start of the production of the product substrate of type T9 is tx. However, when the number of feeders 30 that need to be replaced in the assembly line 13 is large, depending on the number of operators W and the number of automated equipment, sometimes even if time tx has passed since the end of the production of the product substrate of type T8, the picking and equipment operations in the logic process are not completed. In S220, such a delay is calculated. Then, CPU81 makes a graph showing the results of the second simulation and saves the graph in the memory 84 (S230). Specifically, CPU81 makes a graph taking into account the delay calculated in S220 based on the graph obtained in S180 of the first simulation. Figure 8 This is a diagram showing the first simulation and the second simulation in a graph in which the production start time is aligned on a coordinate system in which the horizontal axis is the time and the vertical axis is the number of product substrates produced. Figure 8 In the figure, the solid line represents the result obtained by the first simulation, and the dotted line represents the result obtained by the second simulation. Figure 8 It is known that the dotted line is delayed compared to the solid line. Next, the CPU 81 calculates and stores the work load factor, the operating rate of the assembly line 13, the load distribution of the workers, and the production delay in association with the periods (S240), and ends the simulation.

[0047] The period is an operation interval determined for each product substrate and used to implement the operation required for supplying and collecting the feeder 30 of the substrate production line 10. The periods are numbered in association with the production sequence of the product substrates. Specifically, the period corresponding to the product substrate of type T1 is called #1, the period corresponding to the product substrate of type T2 is called #2, and so on. The start time and end time of the period are calculated in S240 of the second simulation for each period. In addition, all periods can also be set to the same operation interval.

[0048] The load factor of a job is the ratio of the time obtained by subtracting the start time from the end time of the period and dividing it by the scheduled time of the period. The scheduled time of the period is the interval of jobs determined for each period and included in the production plan. If the load factor exceeds 100%, the job is not completed within the scheduled time of the period.

[0049] The operating rate of the mounting line 13 is the ratio of the operating time of the mounting line 13 to the total period time.

[0050] The load distribution of operators is the proportion of each operator status in the entire period of time. The operator status includes "resting", "waiting", "working", "moving", etc. The so-called "waiting" includes, for example, the following situations: although you want to implement the equipment, you have to wait because the picking is not completed, or you have to wait because there is no vacancy in the box (for placing the feeder 30, etc.) placed on the AGV100.

[0051] The production delay is the time delay of the result of the second simulation relative to the result of the first simulation. The production delay can be based on Figure 8 The solid line graph and the dotted line graph are used for calculation.

[0052] Next, the simulation result display routine executed by the management device 80 will be described. Fig. 9 This is a flowchart of the routine. This routine is executed when the operator indicates the display of the simulation results through the input device 85 after the above-mentioned first simulation and second simulation are completed. When the routine is started, the CPU 81 of the management device 80 displays a menu of charts on the display 86 (S310). In the menu, three charts are displayed: (1) a chart showing the load rate and production delay of the operation in each period, (2) a chart showing the operation rate and production delay of the installation line 13 in each period, and (3) a chart showing the load distribution and production delay of the operator in each period. Next, the CPU 81 determines whether the operator has selected the menu (S320). If not, it directly waits. On the other hand, if the menu is selected in S320, the CPU 81 creates a chart that matches the selected menu and displays it on the display 86 (S330), ending this routine.

[0053] If (1) is selected as a graph showing the load rate and production delay of the work in each period in S320, the CPU 81 displays the graph on the display 86 in S330. Fig.10 An example of this chart is shown in FIG. This chart is an example when the operator W is one person. Fig.10 In the figure, the horizontal axis represents the period, the vertical axis on the left represents the load rate of the operation, and the vertical axis on the right represents the delay in production. In addition, the bar graph represents the load rate of the operation (refer to the vertical axis on the left), and the line graph represents the delay in production (refer to the vertical axis on the right). As operations, picking, equipment, and post-processing are exemplified. According to the line graph, it can be seen that a delay in production has occurred since period #7. In addition, if the load rate of the period before period #7 is observed, it can be seen that the load rate of equipment and post-processing exceeds 100%. Therefore, it is speculated that the factor that caused the delay in production in period #7 is that the load of equipment and post-processing is large.

[0054] If (2) is selected as a graph showing the operation rate and production delay of the assembly line 13 in each period in S320, the CPU 81 displays the graph on the display 86 in S330. Fig.11 An example of this chart is shown in FIG. This chart is an example when the operator W is one person. Fig.11 In the figure, the horizontal axis represents the period, and the vertical axis on the left represents the operating rate of the mounting line 13. In addition, the bar graph represents the operating rate of the mounting line 13, and the dotted line graph represents the production delay. In the dotted line graph, if the time delay of the second simulation relative to the first simulation exceeds the predetermined allowed time, a mark (black dot) indicating the occurrence of production delay is displayed, and if it is within the allowed time, no mark is displayed. According to the dotted line graph, it can be seen that the production delay has occurred since period #7. In addition, if the operating rate of the mounting line 13 in the period before period #7 is observed, it can be seen that the operating rate of periods #5 and #6 is as low as about 50% to 60%. As the reason for the low operating rate of periods #5 and #6, it is speculated that there is a possibility of delay in the supply of the feeder 30 to the substrate production line 10 corresponding to periods #5 and #6. In addition, it can be speculated whether the situation in which the supply of the feeder 30 to the substrate production line 10 is delayed is due to the fact that the load of the operations of "period #5" and "period #6" is not large.

[0055] If (3), which is a graph showing the load distribution of operators and production delays in each period, is selected in S320, the CPU 81 displays the graph on the display 86 in S330. Fig.12 An example of this chart is shown in FIG. This chart is an example when the operator W is one person. Fig.12 In FIG. 1 , the horizontal axis represents the period, and the vertical axis on the left represents the operation rate of the installation line 13. In addition, the bar graph represents the load distribution of the operator, and the dotted line graph and Fig.11 The same indicates the delay in production. As mentioned above, the operator load distribution is the proportion of each operator status in the entire period time. Here, "resting", "waiting", "working", and "moving" are exemplified as operator status. According to the dot-line graph, it can be seen that the production delay occurred from period #7. In addition, if the load distribution before period #7 is observed, it can be seen that the proportion of "working" in periods #4 to #6 is as high as about 90%, and the rest is "moving" without rest. Therefore, it is speculated that the factor that caused the production delay in period #7 is that the operator's workload is heavy.

[0056] exist Figure 10 to Figure 12 In the example, the case where the operator W is one person is illustrated, but the production delay occurs as described above. In such a case, the operator increases the number of operators W, for example, and performs the second simulation again. Then, the simulation result display routine is executed to display the chart on the display 86, and this operation is repeated until the production delay is eliminated.

[0057] Here, use Figure 13 to Figure 15 , the following situation is explained: In addition to setting the operator to two people, Figure 10 to Figure 12 The second simulation is performed under the same conditions as those shown in the graph of , and the graphs of (1) to (3) above are displayed.

[0058] Fig.13 This is a graph showing the load factor and production delay of each period when there are two operators (i.e. (1)). Since the line graph moves while the production delay time remains at zero, it can be seen that no production delay occurred during the entire period. In addition, since no production delay occurred, it is inferred that the load factors of picking, equipment, and post-processing were appropriate during the entire period.

[0059] Fig.14 This is a graph showing the operating rate and production delay of the assembly line 13 in each period when there are two operators (i.e., (2)). In this graph, since no dotted line graph (a mark indicating the occurrence of production delay) is shown, it can be seen that no production delay occurred during the entire period. In addition, since no production delay occurred, it is estimated that the operating rate of the assembly line 13 is appropriate.

[0060] Fig.15 This is a graph showing the load distribution of operators and production delays in each period when there are two operators (i.e., (3)). In this graph, since there are two operators, two bar graphs are displayed for one period (the left side is the load distribution of operator W1, and the right side is the load distribution of operator W2). In this graph, since a dotted line graph (a mark indicating the occurrence of production delay) is not displayed, it can be seen that no production delay occurred during the entire period. In addition, since no production delay occurred, it is inferred that the workload of each operator is appropriate.

[0061] Here, the correspondence between the components of this embodiment and the components of the substrate production simulation method disclosed in the present invention is clarified. The first simulation of this embodiment corresponds to step (a) of the present invention, the second simulation corresponds to step (b), and the simulation result display routine corresponds to step (c).

[0062] In the present embodiment described above, the result of the first simulation is the result of the simulation based on the premise that the substrate production line 10 is provided and recovered by the feeder 30 without stagnation. The result of the second simulation is the result of the simulation based on the premise that the substrate production line 10 is provided and / or recovered by the automation equipment and / or the operator W. Then, a production delay association display ( Fig.10 Line graph of production delays, Fig.11 as well as Fig.12 ) and a parameter association display ( Fig.10 A bar chart of the load factor of the job, Fig.11 The bar graph of the operation rate of the installation line 13, Fig.12 Therefore, by observing the output screen, the factors causing the production delay can be easily inferred based on the time point when the production delay occurred and the changes in the parameter correlation display before and after the time point.

[0063] In addition, the production delay is displayed as a line graph or a mark indicating the occurrence of the production delay, and the parameter that becomes the factor of the production delay is displayed as a bar graph. Therefore, it is easy to visually recognize whether there is a production delay or a change in the parameter on the screen.

[0064] Furthermore, in Fig.10 as well as Fig.13 In the above, the load rates of sorting, equipment, and post-processing (operations related to supplying and / or collecting the feeder 30 to the substrate production line 10) are used as parameters that may become factors of production delay. Therefore, based on the time point when the production delay occurs and the changes in the load rates of the operations before and after it, it can be known which period corresponds to the operation with the greater load.

[0065] In addition, Fig.11 as well as Fig.14 In the above, the operating rate of the assembly line 13 is used as a parameter that may cause production delay. Therefore, based on the time point when the production delay occurs and the change in the operating rate of the assembly line before and after it, it can be known which period has a lower operating rate, and as the cause of the lower operating rate, it can be inferred that there is a possibility of a work delay corresponding to the period.

[0066] Then, in Fig.12 as well as Fig.15 In the process, the load distribution of operators is used as a parameter that may cause production delay. Therefore, according to the change of the load distribution of operators before and after the time point when the production delay occurs, it can be known which period has the largest workload of operators.

[0067] In addition, the present invention is not limited to the above-mentioned embodiment at all, and can be implemented in various forms as long as it belongs to the technical scope of the present invention.

[0068] For example, in the above embodiment, Fig.10 In the example, a line graph is used to represent production delays, but it is also possible to display Fig.11Such a dotted line graph (a mark indicating the occurrence of production delay). Fig.11 as well as Fig.12 In the example, production delays are shown as a dotted line graph, but it is also possible to display Fig.10 That kind of line chart.

[0069] In the above embodiment, in order to eliminate Figure 10 to Figure 12 The number of operators may be increased to avoid production delays, but the number of automated equipment (such as automatic warehouses, AGV100) may be increased instead or on this basis.

[0070] In the above-mentioned embodiment, the substrate production line 10 is configured to include a printing device 11. In this case, in the first simulation, the simulation can be performed on the premise that the preparation work of the printing device 11 (for example, the supply work of solder paste to the printing device 11, the replacement work of the mask and the scraper, etc.) is performed without stopping, and in the second simulation, the simulation can be performed on the premise that the preparation work of the printing device 11 is performed by an automated device (for example, AGV) and an operator W. The preparation work of the printing device 11 is a logical process. In this way, in the substrate production line 10 including the printing device 11, the factors of production delay can be easily estimated.

[0071] The substrate production line 10 of the above-mentioned embodiment may also include: a substrate supply device that supplies an unmounted substrate without components mounted thereon toward a printing device 11 located on the upstream side of the mounting line 13; and a substrate receiving device that receives product substrates from a reflow oven 15 located on the downstream side of the mounting line 13. Then, in the first simulation, the simulation may be performed on the premise that the loading operation of loading the unmounted substrate on the substrate supply device and the extraction operation of extracting the product substrate from the substrate receiving device are performed without stagnation, and in the second simulation, the simulation may be performed on the premise that the loading operation and the extraction operation are performed by an automated device (such as AGV100) and / or an operator W. The loading operation and the extraction operation are logical processes. In this way, in the substrate production line 10 including the substrate supply device and the substrate receiving device, the factors causing production delays can be easily inferred.

[0072] In the above embodiment, the management device 80 executes the first simulation and the second simulation, but the present invention is not particularly limited thereto. For example, one or more computers other than the management device 80 may execute the first simulation and the second simulation.

[0073] In the above-described embodiment, the feeder 30 is exemplified as the component supply device, but a tray on which components are placed may be used instead of the feeder 30 or in addition to the feeder 30 .

[0074] The substrate production simulation method disclosed in the present invention may also be configured as follows.

[0075] In the substrate production simulation method disclosed herein, in the step (c), the production delay related display may be a line graph or a mark indicating the occurrence of production delay, and the parameter related display may be a bar graph. In this way, it is easy to visually identify whether there is a production delay or a change in a parameter on the screen.

[0076] In the substrate production simulation method disclosed in the present invention, the parameter that may be a factor of the production delay in the step (c) is the load rate of the operation related to the supply and / or recovery of the component supply device. In this way, based on the time point when the production delay occurs and the change in the load rate of the operation before and after the delay, it can be known which product substrate corresponds to the operation with the larger load.

[0077] In the substrate production simulation method disclosed in the present disclosure, the parameter that may be a factor of the production delay in the step (c) may be the operation rate of the assembly line included in the second result. In this way, based on the time point when the production delay occurs and the changes in the operation rate of the assembly line before and after the delay, it can be known which product substrate has a lower operation rate, and as the cause of the lower operation rate, it can be inferred that there is a possibility of a delay in the operation corresponding to the product substrate.

[0078] In the substrate production simulation method disclosed in the present disclosure, the parameter that may be a factor of the production delay in the step (c) is the load distribution of the operation of the operator included in the second result. In this way, based on the change in the load distribution of the operation of the operators before and after the time point when the production delay occurs, it can be known which product substrate has a larger load on the operator.

[0079] The substrate production simulation method disclosed herein may further include the following steps: (d) in the case where the second result is delayed relative to the first result in the step (c), the number of the automation equipment and / or the number of operators are changed to eliminate the delay of the second result, and the steps (b) and (c) are executed again using the changed number; and (e) the step (d) is repeated until the delay of the second result relative to the first result in the step (c) is within an allowable range. In this way, the number of automation equipment and / or the number of operators that will not cause delays in substrate production can be determined.

[0080] Industrial Applicability

[0081] The substrate production simulation method disclosed in the present disclosure can be applied when producing a substrate on which components are mounted.

[0082] Description of Reference Numerals

[0083] 10: Board production line 11: Printing device 12: Printing inspection device 13: Mounting line 14: Appearance inspection device 15: Reflow oven 16: X-axis rail 18: Component storage warehouse 20: Component mounting machine 20A: Supply area 20B: Storage area 21: Board conveying device 22: Head 23: Head moving mechanism 24: Touch panel display 25: Marking camera 26: Parts camera 27: Nozzle station 28: Mounting control device 30: Feeder 32: Tape reel 33: Tape feeding mechanism 34: Feeder control device 40: Feeder table 42: Slot 45: Connector 50: Loader 50A: Upper transfer area 50B: Lower transfer area 51: Loader moving mechanism 53: Feeder transfer mechanism 55: Encoder 57: Loader control device 60: Feeder storage 80: Management device 81: CPU 82: ROM 83: RAM 84: Memory 85: Input device 86: Display 100: AGV 101: AGV moving mechanism 103: Feeder transfer mechanism 105: Position sensor 107: AGV control device A1: First area A2: Second area F: Substrate production layers W, W1, W2: Operator.

Claims

1. A substrate production simulation method, simulating a product substrate on which components are mounted using a substrate production line, wherein the substrate production line includes a mounting line formed by arranging a plurality of component mounting machines along a substrate conveying direction, wherein the component mounting machines mount the components supplied from a component supply device onto the substrate, wherein: The substrate production simulation method comprises the following steps: (a) simulating the production of a plurality of product substrates by the substrate production line on the premise that the component supply device supplies and recovers the substrate production line without stopping, thereby obtaining a first result; (b) simulating the production of the plurality of product substrates by the substrate production line on the premise that the component supply device is provided and / or recovered by the automation equipment and / or the operator, thereby obtaining a second result; (c) outputting a production delay association display and a parameter association display on the same screen, wherein the production delay association display displays the production delay of the second result relative to the first result in association with the product substrate, and the parameter association display displays the parameters contained in the second result that may become a factor of the production delay in association with the product substrate; (d) if the second result is delayed relative to the first result in the step (c), changing the number of the automated equipment and / or the number of the operators to eliminate the delay of the second result, and performing the steps (b) and (c) again using the changed number; as well as (e) Repeating the step (d) until the delay of the second result with respect to the first result in the step (c) falls within an allowable range.

2. The substrate production simulation method according to claim 1, wherein: In the step (c), the production delay related display is a line graph or a mark indicating the occurrence of production delay, and the parameter related display is a bar graph.

3. The substrate production simulation method according to claim 1 or 2, wherein: In the step (c), the parameter that may become a factor of the production delay is the load factor of the work related to the supply and / or collection of the component supply device.

4. The substrate production simulation method according to claim 1 or 2, wherein: In the step (c), the parameter that may be a factor of the production delay is the operating rate of the mounting line included in the second result.

5. The substrate production simulation method according to claim 1 or 2, wherein: In the step (c), the parameter that may be a factor of the production delay is the load distribution of the work of the operator included in the second result.

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