Production management method and production management system

Abstract

A production management method in a system provided with a production line provided in a production plant, a plurality of cameras provided in the production plant or the production line and connected to a network, and a terminal connected to the network, selects, from the terminal, a camera to be used as a target from among the plurality of cameras, displays an image captured by the camera as the target on a display portion of the terminal, and confirms a state of the production line or a state of a worker performing work in the production line based on the image displayed on the display portion.

Description

Technical Field

[0001] This specification discloses a production management method and a production management system. Background Technology

[0002] Previously, as a work management system, the following solution was proposed: When an equipment installed in the production workshop malfunctions, a target operator is selected from multiple operators based on the error information, and an instruction is output indicating that the target operator should perform a confirmation operation to verify the accuracy of the operation. Image data of the target operator performing the operation is acquired from a camera installed in the production workshop, the acquired image data is analyzed to calculate the accuracy of the confirmation operation, and guidance information corresponding to the calculated accuracy (information for implementing education and training, OJT) is output (for example, see Patent Document 1). Existing technical documents Patent documents

[0003] Patent document 1: Japanese Patent Application Publication No. 2022-124655. Summary of the Invention The problem that the invention aims to solve

[0004] However, although Patent Document 1 describes calculating the accuracy of operator confirmation based on image data taken by cameras in the production workshop, there is still room for improvement as there is a need for production line managers and others to more easily grasp the status of the production line and the status of operators working on the production line.

[0005] The main purpose of this disclosure is to enable production line managers and others to more easily grasp the status of the production line and the status of the workers operating on the production line without having to go to the site. Methods for solving problems

[0006] The following means were employed in this disclosure to achieve the aforementioned main objectives.

[0007] The production management method disclosed herein manages production within a system comprising a production line located in a production workshop, multiple cameras located in the production workshop or on the production line and connected to a network, and terminals connected to the network. The essence of the production management method is that, Select the camera to be used from the plurality of cameras from the terminal. The image captured by the camera (which is the target) is displayed on the display unit of the terminal. The status of the production line or the status of the workers operating on the production line is confirmed based on the image displayed on the display unit.

[0008] In the production management method disclosed herein, production line managers can more easily grasp the status of the production line and the status of the operators working on the production line by selecting a camera as the target from multiple cameras installed in the production workshop or production line and viewing the image displayed on the terminal display unit, without having to go to the site.

[0009] The production management system disclosed herein manages production lines located in production workshops. The essence of the production management system is that it possesses: Multiple cameras, installed in the production workshop or on the production line and connected to a network; and The terminal is connected to the network and has a display unit and a control unit. When the start-up waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when one of the devices on the production line malfunctions, the control unit accepts the selection of one of the plurality of cameras as the target camera and displays the image captured by the target camera on the display unit.

[0010] In this disclosed production management system, when the start-up waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when one of the devices on the production line malfunctions, the system accepts the selection of one of the multiple cameras installed in the production workshop or on the production line as the target camera, and displays the image captured by the target camera on the terminal display. Production line managers and others can view the images displayed on the terminal display at appropriate times, and can more appropriately grasp the status of the production line and the status of the operators working on the production line without going to the site. Attached Figure Description

[0011] Figure 1 It is a rough structural diagram of the production line and production management system. Figure 2 This is a flowchart illustrating an example of production management processes. Figure 3 This is an explanatory diagram illustrating an example of the actions of a production management system when a device on the production line generates a start-up wait (U1). Figure 4 This is an explanatory diagram illustrating an example of the actions of a production management system that causes a production line stop (U2). Figure 5 This is an explanatory diagram illustrating an example of the confirmation steps taken by the production line manager when confirming the status of the production line and the operators working on the production line (U3). Figure 6 This is an explanatory diagram illustrating an example of the actions of the production management system when an abnormality (U11) occurs in a device on the production line. Figure 7 This is an explanatory diagram illustrating an example of the confirmation steps (U12) taken by an operator or production line manager when confirming the status of devices or substrates on the production line. Detailed Implementation

[0012] Next, refer to the appendix Figure 1 The manner in which this disclosure is implemented will be described.

[0013] Figure 1 This is a schematic diagram of the production line 1 and the production management system 10. Production line 1 is a production line for producing substrates with electronic components mounted on them. It includes a printing device 2, a printing inspection device, a storage device 3, a multiple component mounting device 4, a mounting inspection device (not shown), a reflow device 5, a reflow inspection device (not shown), a loader 6, and a production line management device 7 for managing the entire production line 1. The printing device 2, printing inspection device, storage device 3, multiple component mounting device 4, mounting inspection device, reflow device 5, and reflow inspection device on the production line are arranged in a row in this order along the transport direction of the substrate S.

[0014] The printing apparatus 2 prints solder onto the wiring pattern of the substrate S. The printing apparatus 2 includes a substrate transport device for transporting the substrate S, a substrate support device for supporting the substrate S such that the printing surface of the substrate S contacts the lower surface of the screen mask, a printing head including a squeegee, a head moving device for moving the printing head, a solder replenishing device for replenishing solder onto the screen mask, and a printing control device for controlling the entire printing apparatus 2. A printing inspection device inspects the state of the solder printed on the substrate S by the printing apparatus 2.

[0015] Storage device 3 stores the feeders intended for use in component mounting device 4, and stores the feeders that have been used up after use in component mounting device 4. The installation of feeders intended for use into component mounting device 4 and the retrieval of used feeders from component mounting device 4 are carried out by loader 6. Loader 6 includes a loader body including a receiving section for storing feeders, a feeder transfer device for transferring feeders between the receiving section and storage device 3 and component mounting device 4, a loader moving device for moving the loader body along production line 1 between storage device 3 and each component mounting device 4, and a loader control device for controlling the entire loader 6.

[0016] The component mounting device 4 adsorbs components supplied from the feeder and mounts them onto the mounting position of the substrate S. It includes a feeder table for mounting multiple feeders, a substrate transport device for transporting the substrate S, a substrate support device for supporting the substrate S, a mounting head that holds one or more nozzles in a lifting manner, a head moving device that moves the mounting head horizontally (XY direction), a marking camera, a component camera for confirming the adsorption status of components adsorbed by the nozzles, a nozzle station for accommodating replacement nozzles, and a mounting control device for controlling the entire component mounting device 4. The mounting inspection device inspects the mounting status of the components mounted on the substrate S by the component mounting device 4.

[0017] The reflow soldering device 5 heats the substrate S, melting and solidifying the solder on the substrate S, and electrically connecting the components mounted on the substrate S to the wiring pattern of the substrate S. The reflow inspection device inspects the condition of the components on the substrate S that have undergone reflow treatment.

[0018] The production line management device 7 is a computer including a CPU, ROM, RAM, and a storage device. The storage device stores production plans and production information related to the production of substrates S. The production plan includes the production quantity of each type of substrate S when producing multiple types of substrates S, the production start time, etc. The production information includes component information related to the components to be installed by each of the multiple component mounting devices 4, nozzle information related to the nozzles used to pick up the components, the installation sequence of each component, the target installation position, etc. The production line management device 7 is connected to the printing device 2, the printing inspection device, the storage device 3, the multiple component mounting devices 4, the mounting inspection device, the reflow device 5, and the reflow inspection device via wired or wireless means, sending various command signals to each device and receiving status information (e.g., information indicating operating conditions such as production in progress, stoppage, or abnormality occurrence) from each device.

[0019] The production management system 10 is mainly used to confirm the status of production line 1 and the status of the workers M working on production line 1. It has a production management device 11, multiple workshop cameras 21, and multiple device cameras 22 to control the entire production management system 10. The production management device 11 is a computer that includes a CPU 11a, ROM 11b, RAM 11c, HDD, SSD and other storage units 11d, and is connected to input devices 12 such as a keyboard and mouse, and a display 13.

[0020] Workshop cameras 21 are mounted on the ceiling or walls of production workshop F (production line 1) to capture images of the workshop from a top-down perspective. Device cameras 22 capture images of the interiors of various devices (e.g., printing device 2, component mounting device 4) within production line 1. In this embodiment, multiple devices are provided for each device to capture images of their interiors from different positions. Each workshop camera 21 and each device camera 22 includes: a horizontal rotation adjustment mechanism for rotating the camera body horizontally, a horizontal rotation adjustment motor, a vertical rotation adjustment mechanism for rotating the camera body vertically, a vertical rotation adjustment motor, a focus adjustment mechanism for adjusting the focus, and a focus adjustment motor. Each workshop camera 21 and each device camera 22 is remotely operated via network 14 from an external source (e.g., a production management device 11 or a portable terminal carried by the operator M) to drive the horizontal rotation adjustment motor, the vertical rotation adjustment motor, and the focus adjustment motor, thereby adjusting the camera body's shooting angle (horizontal rotation angle, vertical rotation angle) and the focus.

[0021] Next, the operation of the production management system 10 will be explained. Figure 2 This is a flowchart of an example of production management processing performed by the CPU 11a of the production management device 11.

[0022] In the production management process, the CPU 11a of the production management device 11 first obtains the status (status information) of each device on the production line from the production line management device 7 (S100). Next, based on the obtained status information, the CPU 11a determines whether a particular device on the production line is in a start-up waiting state (S102). Here, the start-up waiting state refers to the following state: production preparation (changeover adjustment) is completed and the device is waiting for the production start time to arrive, and the operator M presses the start button. If the CPU 11a determines that a particular device is in a start-up waiting state, it determines whether the start-up waiting time exceeds a threshold (S104). If the production management device 11 determines that the start-up waiting time exceeds the threshold, it proceeds to S114.

[0023] On the other hand, if CPU11a determines in S102 that all devices are not in the start-up waiting state and in S104 that the start-up waiting time has not exceeded the threshold, then it determines whether the production line 1 is in a stopped state (S106). If CPU11a determines that the production line is in a stopped state, then it determines whether the stop time of the production line exceeds the threshold (S108). If CPU11a determines that the stop time of the production line exceeds the threshold, then it proceeds to S114.

[0024] On the other hand, if CPU11a determines in S106 that production line 1 has not stopped and in S108 that the stop time has not exceeded the threshold, it determines whether a device in production line 1 has experienced an erroneous device abnormality (S110). If CPU11a determines that it is not in a device abnormality state, it ends the process.

[0025] If CPU11a determines in S102 and S104 that a device on production line 1 is in a start-up waiting state and its start-up waiting time exceeds a threshold, in S106 and S108 that production line 1 is in a stop state and its stop time exceeds a threshold, or in S110 that a device is in an abnormal state, then it notifies the production line manager and operator M of the status of the corresponding device and the corresponding countermeasures (S112). Notification to the production line manager is made by displaying the status information of the corresponding device on the display 13 of the production management device 11. Notification to operator M is made by sending the status information of the corresponding device to a portable terminal carried by operator M, which then displays the information on the portable terminal's display. For example, if a device on production line 1 is in a start-up waiting state, such as... Figure 3 As shown, when the start-up waiting time exceeds a threshold, operator M is notified of a message including that they are in a start-up waiting state, the identification information of the corresponding device, and that the start button should be pressed. Upon receiving the notification, operator M can then proceed to the corresponding device and press the start button. Additionally, for example, if production line 1 is in a stopped state, such as... Figure 4 As shown, when the production line stop time (previous process waiting time) exceeds the threshold, the operator M and the production line manager are notified of a message including the occurrence of a stop status, which can prompt the operator M and the production line manager to respond to the stop status of production line 1.

[0026] Next, CPU 11a displays the image from the workshop camera 21 and the thumbnail images from each device camera 22 on the display 13 (S114). Then, CPU 11a processes the selection of the device camera 22 (object camera) used to check the internal conditions of the corresponding device in each device of production line 1 (S116). The object camera is selected, for example, by the production line manager operating the input device 12 to select the image from the thumbnail images of each device camera 22 displayed on the display 13 for details to be checked. When an object camera is selected, CPU 11a processes the input device 12 to remotely adjust the angle of the object camera (S118) and the focus of the object camera to remotely (S120). Finally, CPU 11a displays the object camera image on the display 13 (S122), ending the process. Alternatively, CPU 11a can also store (record) the object camera image in the storage unit 11d.

[0027] Here, for example, if production line 1 stops, the production line manager who receives the production line stop notification, such as... Figure 5 As shown, after confirming the notification message, the status of production line 1 and the status of the operator M working on production line 1 are confirmed based on the image from workshop camera 21. Next, in order to investigate the cause of the production line stoppage, the production line manager selects the appropriate device camera 22 (object camera) from among multiple device cameras 22. After adjusting the angle and focus of the object camera, the status of the corresponding device is confirmed using the image from the object camera displayed on monitor 13. Thus, appropriate countermeasures matching the device's status can be determined and instructed to the operator M. For example, if a component adsorption malfunction occurs in the device, and the image from the corresponding device's device camera 22 confirms that the component has fallen onto the substrate, the operator M can be instructed to remove the component that has fallen onto the substrate.

[0028] Alternatively, the operator M can use a portable terminal to remotely operate the workshop camera 21 and the device camera 22, and verify the images. For example, in the event of an malfunction in a device on production line 1, such as... Figure 6 As shown, operator M, upon receiving a notification of an abnormal device status, can understand the details of the abnormality and corresponding countermeasures by confirming the notification message. Furthermore, as... Figure 7 As shown, when operator M is unable to determine whether countermeasures for abnormal equipment conditions can be implemented, or when component adsorption abnormalities occur repeatedly and there is a possibility that components may fall onto the substrate, after confirming the status of production line 1 based on the image from workshop camera 21, operator M selects the appropriate device camera 22 (object camera) from among multiple device cameras 22. After adjusting the angle and focus of the object camera, operator M uses the image from the object camera to confirm the situation inside the corresponding device. Thus, if the device is not abnormal, operator M can resolve the abnormal equipment condition and restart production; if there are fallen components on the substrate S, operator M can remove them.

[0029] Here, the correspondence between the main elements of the embodiments and the main elements of the present disclosure as described in the claims will be explained. That is, the production line 1 of this embodiment is an example of the production line of the present disclosure, the workshop camera 21 and the device camera 22 are examples of cameras, the production management device 11 and the portable terminal are examples of terminals, and the display 13 is an example of a display unit. In addition, the workshop camera 21 is an example of a first camera, and the device camera 22 is an example of a second camera.

[0030] Furthermore, this disclosure is not limited to the above-described embodiments. It is self-evident that it can be implemented in various ways as long as it falls within the technical scope of this disclosure.

[0031] For example, in the above embodiment, the production management system 10 is provided with multiple workshop cameras 21, but a workshop camera 21 can also be a single camera. Additionally, the production management system 10 is provided with multiple device cameras 22 for each device on the production line 1, but it can also be provided with one device camera 22 for each device.

[0032] In the above embodiment, the production management system 10 is provided with multiple workshop cameras 21 and multiple device cameras 22, but one of the workshop cameras 21 and device cameras 22 may be omitted.

[0033] In the above embodiments, the workshop camera 21 and the device camera 22 are configured to be able to be adjusted in angle and focus remotely from the production management device 11 and the portable terminal. However, the focus can also be adjusted automatically after the angle has been adjusted remotely. Alternatively, the angle adjustment can be performed manually in advance by the operator M or others.

[0034] In the production management method of this disclosure described above, production line managers can more easily grasp the status of the production line and the status of the workers operating on the production line by selecting a camera as the target from multiple cameras installed in the production workshop or production line and viewing the images displayed on the terminal display unit, without having to go to the site.

[0035] In this production management method of the present disclosure, the camera, including angle adjustment or focus adjustment, can be adjusted remotely from the terminal, and the image captured by the camera can be displayed on the display unit of the terminal. In this way, the image of the desired part can be clearly displayed using the camera, allowing production line managers and others to more accurately grasp the status of the production line and the status of the workers operating on the production line.

[0036] Furthermore, in the production management method disclosed herein, the plurality of cameras may include a first camera that captures the entire production line and a plurality of second cameras that capture images of the interiors of each device on the production line. The image captured by the first camera is displayed on the display unit. A terminal selects a second camera from the plurality of second cameras to be used as the target camera, and the image captured by the target second camera is displayed on the terminal's display unit. In this way, by sequentially switching between the images from the first and second cameras, the status of the production line and the status of the workers operating on the production line can be efficiently confirmed.

[0037] Furthermore, in the production management method disclosed herein, the terminal may be notified when the start-up waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when a malfunction occurs in one of the devices on the production line. This allows production line managers to view camera images at appropriate times to confirm the status of the production line.

[0038] Alternatively, a production management system can be used instead of a production management method in this disclosure. In the production management system of this disclosure, when the start-up waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when a device on the production line malfunctions, the system accepts the selection of one of multiple cameras installed in the production workshop or on the production line as the target camera, and displays the image captured by the target camera on the terminal display. Production line managers can view the images displayed on the terminal display at appropriate times, and can more appropriately grasp the status of the production line and the status of the workers operating on the production line without going to the site.

[0039] This specification also discloses the technical idea of ​​changing "the production management method according to claim 1 or 2" to "the production management method according to any one of claims 1 to 3" in the original claim 4. Industrial applicability

[0040] This disclosure can be applied to the manufacturing industry, including production lines and production management systems. Symbol Explanation

[0041] 1 Production line, 2 Printing equipment, 3 Storage equipment, 4 Component mounting equipment, 5 Reflow equipment, 6 Loader, 7 Production line management equipment, 10 Production management system, 11 Production management equipment, 11a CPU, 11b ROM, 11c RAM, 11d Storage unit, 12 Input device, 13 Display, 14 Network, 21 Workshop camera, 22 Device camera, F Production workshop, M Operator, S Substrate.

Claims

1. A production management method for managing production within a system. The system includes: a production line installed in a production workshop; multiple cameras installed in the production workshop or on the production line and connected to a network; and a terminal connected to the network. In the aforementioned production management method Select the camera to be used from the plurality of cameras from the terminal. The image captured by the camera (which is the target) is displayed on the display unit of the terminal. The status of the production line or the status of the workers performing operations on the production line is confirmed based on the images displayed on the display unit.

2. The production management method according to claim 1, wherein, The camera, which is the target, is adjusted remotely via the terminal, including angle adjustment or focal length adjustment, and the image captured by the camera is displayed on the display of the terminal.

3. The production management method according to claim 1 or 2, wherein, The plurality of cameras includes a first camera that captures the entire production line, and a plurality of second cameras that capture the interior of each device on the production line. The image captured by the first camera is displayed on the display unit. Select the second camera to be used from the plurality of second cameras from the terminal. The image captured by the second camera, which is the object, is displayed on the display unit of the terminal.

4. The production management method according to claim 1 or 2, wherein, When the start-up waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when one of the devices on the production line malfunctions, this situation will be notified to the terminal.

5. A production management system for managing production lines located in a production workshop. The production management system has the following features: Multiple cameras are installed in the production workshop or on the production line and are connected to a network; and The terminal, connected to the network, has a display unit and a control unit. When the start-up waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when one of the devices on the production line malfunctions, the control unit accepts the selection of one of the plurality of cameras as the target camera and displays the image captured by the target camera on the display unit.

Images