Cell management system and cell management method

Abstract

The present invention relates to: acquiring history information about maintenance of a unit attached to a production device; identifying a unit for which maintenance has been performed, based on the history information; acquiring actual result information indicating actual results of production using the unit after the maintenance, for a plurality of times of maintenance performed on the identified unit; predicting a limit of use for which the unit cannot be used for production even if the maintenance is performed, based on at least one of the history information and the actual result information; and outputting information indicating the unit that is inferred to require an alternative unit, based on the predicted limit of use.

Description

Technical Field

[0001] This disclosure relates to a unit management system and a unit management method for managing units that are detachably attached to production equipment. Background Technology

[0002] When production equipment with attached units malfunctions, it may require repair of the malfunctioning unit, alternative operations on another facility, etc., thereby hindering product production. Various methods have been proposed to reduce the impact of malfunctions. Patent Document 1 discloses a production management device comprising: a fault determination unit that detects signs of malfunction by monitoring the status of production equipment included in a production line for producing products using sensors; a repair determination unit that calculates the repair method and repair time for the malfunction; and a recovery plan creation unit that creates a recovery plan (e.g., repair method, repair time, and production plan change suggestions). In the production management device disclosed in Patent Document 1, the recovery plan creation unit creates a recovery plan that maximizes production indicators across the entire factory and controls the periods when the malfunctioning production equipment cannot be used, thereby improving the overall production evaluation indicators of the factory.

[0003] Reference List

[0004] Patent documents

[0005] Patent Document 1: JP7056574B Summary of the Invention

[0006] Technical issues

[0007] However, in the related technologies, including Patent Document 1, the recovery plan is created based on the premise that the faulty production equipment or unit must be recovered through maintenance. However, there are units that cannot be recovered through maintenance depending on their usage status, etc., and there is room for further improvement in order to properly manage units, including those that may not be recoverable through maintenance.

[0008] Therefore, the purpose of this disclosure is to provide a unit management system and a unit management method that can properly manage units that need to be maintained.

[0009] Solution to the problem

[0010] The unit management system disclosed herein includes: a designation unit configured to acquire historical information indicating the history of maintenance performed on units of production equipment detachably attached to the production product and designate units for which maintenance has been performed; an acquisition unit configured to acquire record information indicating production records of the unit after maintenance for multiple maintenance operations performed on the designated unit; a prediction unit configured to predict, based on at least one of the historical information and the record information, the usage limit time that the unit cannot be used for production even after maintenance, or the usage limit count indicating the number of uses until the unit cannot be used for production even after maintenance; and an output unit configured to output information indicating units estimated to require alternative units based on the predicted usage limit time or the predicted usage limit count.

[0011] The cell management method disclosed herein includes: acquiring historical information indicating the history of maintenance performed on cells of production equipment detachably attached to a production product; designating cells for which maintenance has been performed based on the historical information; acquiring record information indicating production records of the cells after maintenance for multiple maintenance operations performed on the designated cells; predicting, based on at least one of the historical information and the record information, the usage limit time that the cells cannot be used for production even after maintenance, or indicating the usage limit count of the number of uses until the cells cannot be used for production even after maintenance; and outputting information indicating cells that are estimated to require alternative cells based on the predicted usage limit time or the predicted usage limit count.

[0012] Beneficial effects of the invention

[0013] According to this disclosure, units that require maintenance can be appropriately managed. Attached Figure Description

[0014] [ Figure 1 ] Figure 1 This is a diagram illustrating the configuration of an installation system according to an embodiment of the present disclosure.

[0015] [ Figure 2 ] Figure 2 This is a front view showing the configuration of the main parts of the component mounting equipment included in the mounting line according to an embodiment of the present disclosure.

[0016] [ Figure 3 ] Figure 3 This is a block diagram illustrating a configuration example of an installation system according to an embodiment of the present disclosure.

[0017] [ Figure 4 ] Figure 4 This is a diagram illustrating an example of the configuration of unit information generated in an installation system according to an embodiment of the present disclosure.

[0018] [ Figure 5 ] Figure 5 This is a graph illustrating the prediction of usage limit counts based on sensor values ​​after maintenance in an installation system according to an embodiment of the present disclosure.

[0019] [ Figure 6 ] Figure 6 This is a diagram illustrating an example of a unit replacement information display screen shown on a display unit included in a management computer according to an embodiment of the present disclosure.

[0020] [ Figure 7 ] Figure 7 This is a flowchart illustrating a unit management method according to an embodiment of the present disclosure. Detailed Implementation

[0021] In the following, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. The configurations, shapes, etc., described later are examples for illustrative purposes and may be appropriately changed according to the specifications of the installation system, installation line, management computer, component installation equipment, etc. In the following, corresponding elements in all the drawings are indicated by the same reference numerals, and repeated descriptions are omitted. Figure 1 In the section described later, the two axes orthogonal to each other in the horizontal plane are referred to as the X-axis in the substrate transport direction. Figure 1 The left and right directions) and the Y-axis orthogonal to the substrate transport direction (in the ... right and left directions) Figure 1 (Up and down directions in the middle). Figure 2 And in the section described later, the Z-axis ( Figure 2 The vertical direction (in the image) is shown as the height direction orthogonal to the horizontal plane.

[0022] First, refer to Figure 1 Describe the configuration for installing System 1. Figure 1 This diagram illustrates the configuration of an installation system according to an embodiment of the present disclosure. The installation system 1 is configured such that three mounting lines L1 to L3 arranged on a floor F are connected via a wired or wireless communication network 2 and managed by a management computer 3. Each of the mounting lines L1 to L3 is formed by connecting multiple production devices, including printing equipment and component mounting equipment described later, and has the function of producing a circuit board (mounting board) on a substrate in which components are mounted. The number of mounting lines L1 to L3 included in the installation system 1 is not limited to three, and may be one, two, four, or more.

[0023] On floor F, maintenance support equipment 4 is located away from installation lines L1 to L3. Maintenance support equipment 4 is connected to management computer 3 via communication network 2. Maintenance support equipment 4 has the function of automatically performing maintenance on nozzles, feeders, heads, etc., which are detachably attached to the component installation equipment. Maintenance support equipment 4 can be installed on a different floor from floor F, where installation lines L1 to L3 are located, or in a different factory. In addition to the configuration of maintenance support equipment 4 communicating with management computer 3 via communication network 2, maintenance results can also be indirectly sent to management computer 3 via the Internet or other means.

[0024] Next, we will refer to Figure 1 The detailed configuration of mounting lines L1 to L3 is described below. Mounting lines L1 to L3 have the same configuration, and mounting line L1 will be described below. Mounting line L1 is formed by connecting production equipment such as printing equipment M1, component mounting equipment M2 to M5, and reflow equipment M6 in series from upstream (left side of the page) to downstream (right side of the page) along the substrate conveying direction. The production equipment is connected to management computer 3 via communication network 2. Mounting line L1 is a group of production equipment connected via communication network 2, and the production equipment may not be physically connected to each other.

[0025] exist Figure 1 In this process, printing equipment M1 has the function of printing solder paste onto a substrate via a screen mask. Each of the component mounting equipment M2 to M5 has the function of picking up components supplied from a feeder via a nozzle mounted on a head, conveying the components, and mounting them onto mounting points on the substrate on which solder paste has been printed. Reflow equipment M6 has the function of heating the substrate on which components are mounted to melt the solder, and then solidifying the solder to solder the components to the substrate. As described above, printing equipment M1, component mounting equipment M2 to M5, and reflow equipment M6 are production equipment with the function of producing circuit boards (products) on a substrate in which components are mounted.

[0026] The management computer 3 performs processes such as production management of the circuit boards manufactured in each of the assembly lines L1 to L3, creation of programs and data for each production equipment used to manufacture the circuit boards, and downloading to each production equipment. In addition, the management computer 3 also functions as a maintenance management device, which manages the maintenance performed on the units (nozzles, feeders, heads, cameras, motors, etc.) that are detachably attached to each of the component mounting devices M2 to M5.

[0027] Next, we will refer to Figure 2 Describe the configuration of component installation devices M2 to M5. Figure 2This is a front view showing the configuration of the main parts of the component mounting equipment included in the mounting line according to an embodiment of the present disclosure. A substrate transport unit 6 is disposed along the X-axis at the center of the base 5. The substrate transport unit 6 transports a substrate 7 transported upstream to the working position and holds the substrate 7. Furthermore, the substrate transport unit 6 moves the substrate 7 downstream after the component mounting work is completed.

[0028] The substrate transport unit 6 includes a motor for transporting the substrate 7 via a conveyor cycle, a sensor for detecting the stop position of the substrate 7, etc. The substrate transport unit 6 detects transport errors such as the substrate 7 not stopping at a predetermined stop position. During maintenance, the drive state of the motor and the state of the sensor in the substrate transport unit 6 are adjusted. The motor and sensor of the substrate transport unit 6 are replaceable units U.

[0029] exist Figure 2 In this assembly, component supply units 8 are respectively located on the front and rear sides of component mounting devices M2 to M5. Each component supply unit 8 has a carriage 9, in which multiple feeders 10 are pre-installed on feeder bases 9a. A reel 12, which holds component belt 11 in a wound state, is held in the carriage 9. Component D is supplied to component supply position 10a by feeding the component belt 11 pulled from the reel 12 to the component supply position 10a at a pitch.

[0030] Each of the feeders 10 includes a motor for conveying the component belt 11, a sensor for detecting the position of the component belt 11, etc. The feeder 10 detects supply errors such as component D not being supplied to the predetermined position 10a. During maintenance, the feeder 10 is adjusted using the maintenance support device 4. The feeder 10 is a replaceable unit U.

[0031] exist Figure 2 In this assembly, the head 14 of the suction nozzle 13, on which the holding component D is mounted, is positioned above the base 5. The head 14 moves between the component supply unit 8 and the substrate 7, which is held in a working position by the substrate transfer unit 6, via a head moving mechanism 15. Accordingly, a component mounting operation is performed to mount the component D, which is taken from the feeder 10 of the component supply unit 8 by the suction nozzle 13, onto the mounting point of the substrate 7.

[0032] The head 14 includes a motor for raising and lowering the nozzle 13, a sensor for measuring the airflow rate into the installed nozzle 13, etc. The head 14 detects suction errors, such as the component D not being properly held by the nozzle 13. During maintenance, adjustments are made to the nozzle 13 and head 14 using the maintenance support equipment 4. The nozzle 13 and head 14 are replaceable units U.

[0033] The head movement mechanism 15 is an XY robot that includes a linear drive mechanism and moves the head 14 in a horizontal plane (X-axis and Y-axis directions). The head movement mechanism 15 detects stopping errors such as the moving head 14 failing to stop at a predetermined position within a predetermined time, and stabilization errors such as vibration failing to converge within a predetermined stabilization time upon reaching the target position. During maintenance, the drive state of the linear drive mechanism of the head movement mechanism 15 is adjusted. The linear drive mechanism of the head movement mechanism 15 is a replaceable unit U.

[0034] exist Figure 2 In this configuration, a component identification camera 16 is positioned between the component supply unit 8 and the substrate transfer unit 6. When the head 14 of the component D, removed from the feeder 10, moves above the component identification camera 16, the camera images the component D held by the nozzle 13. The holding posture of the component D is identified from the imaging result. A head camera 17, which moves integrally with the head 14 via a head movement mechanism 15, is attached above the base 5.

[0035] As the head 14 moves, the head camera 17 moves above the substrate 7 positioned by the substrate transfer unit 6 and images the substrate markings (not shown) provided on the substrate 7. The position of the substrate 7 is identified from the imaging results. During the component mounting operation of the head 14 on the substrate 7, the mounting position is corrected by taking into account the imaging results of the component identification camera 16 on the component D and the imaging results of the head camera 17 on the substrate markings.

[0036] Each of the component recognition camera 16 and the head camera 17 includes an imaging unit and an illumination unit for illuminating the imaging target. In the component recognition camera 16 and the head camera 17, recognition errors are detected where the imaging target is not properly recognized due to factors such as reduced illumination of the illumination unit. During maintenance, the state of the optical system and the illumination unit included in the component recognition camera 16 and the head camera 17 are adjusted. The component recognition camera 16 and the head camera 17 are replaceable units.

[0037] As described above, the motor and sensor of the substrate transfer unit 6, the feeder 10, the nozzle 13, the head 14, the linear drive mechanism of the head moving mechanism 15, the component identification camera 16 and the head camera 17 are detachably attached to the component mounting equipment M2 to M5 (production equipment) included in the mounting lines L1 to L3 for producing circuit boards.

[0038] Next, we will refer to Figure 3 Describe the configuration for installing System 1. Figure 3This is a block diagram illustrating an example configuration of an installation system according to an embodiment of the present disclosure. Here, the configuration will be primarily described in relation to the function of a unit management system that manages units U (feeders 10, heads 14, and nozzles 13) detachably attached to component mounting devices M2 to M5. Mounting lines L1 to L3 have the same configuration, and mounting line L1 will be described below. Furthermore, the devices included in mounting line L1 have the same configuration, and component mounting device M2 will be described below.

[0039] exist Figure 3 In this assembly, the component mounting equipment M2 includes a work control unit 20, a work unit 21, an equipment storage unit 22, a monitoring unit 23, and an equipment communication unit 24. The work control unit 20 controls the work unit 21 based on various data stored in the equipment storage unit 22, thereby controlling the component mounting work performed by the component mounting equipment M2. The work control unit 20 also controls the solder printing work in the printing equipment M1 and the substrate heating work in the reflow equipment M6.

[0040] Monitoring unit 23 monitors the production operations of unit U, such as the supply of component D by feeder 10 and the adsorption of component D by head 14 and nozzle 13 in component mounting equipment M2, and notifies management computer 3 of operation time, number of uses, and output values ​​of sensors included in unit U. Monitoring unit 23 also monitors for operational errors occurring in component mounting equipment M2 during circuit board production and notifies management computer 3 of the time of the error, the nature of the error, and information about unit U associated with the error. Device communication unit 24 is a communication interface that sends and receives signals and data from other devices and management computer 3 via communication network 2.

[0041] exist Figure 3 In this system, the management computer 3 includes a management control unit 30, a management storage unit 31, a collection unit 32, a designation unit 33, an acquisition unit 34, a prediction unit 35, an output unit 36, a display processing unit 37, and a management communication unit 40. Processing units such as the management control unit 30, collection unit 32, designation unit 33, acquisition unit 34, prediction unit 35, output unit 36, and display processing unit 37 are implemented, for example, by a memory storing the control program executed by each processing unit and a processor executing that control program.

[0042] Input unit 38 is an input device such as a keyboard, touch panel, or mouse, and each processing unit included in management computer 3 executes processes based on operation instructions or data input from input unit 38. Display unit 39 is a display device such as a liquid crystal panel, and in addition to various screens, display processing unit 37 also displays various types of information on display unit 39. Management communication unit 40 is a communication interface, and sends and receives signals and data from maintenance support equipment 4 and production equipment on installation lines L1 to L3 via communication network 2.

[0043] exist Figure 3 In this system, the management storage unit 31 is a storage device that stores various types of information. The management storage unit 31 stores information such as instructions for production plans and maintenance plans. The management storage unit 31 is implemented using, for example, flash memory or a hard disk drive (HDD). In addition to component installation data, the management storage unit 31 also stores historical information 31a, record information 31b, unit information 31c, etc. Unit information 31c stores various types of information about the unit U used in the installation system 1.

[0044] exist Figure 3 In this process, the collection unit 32 collects information about the maintenance performed on the unit U from the maintenance support equipment 4 and stores this information as historical information 31a in the management storage unit 31. In addition, the collection unit 32 collects information about the maintenance performed by the maintenance worker while the unit U is installed on the component mounting equipment M2 to M5 from information terminals (not shown) carried by the maintenance worker and stores this information as historical information 31a.

[0045] The collection unit 32 collects information about the maintenance performed on units U that were removed from the component installation equipment M2 to M5, and stores this information as historical information 31a. Historical information 31a stores information such as the unit U that has been maintained, the date and time of maintenance, and the content of maintenance.

[0046] As described above, historical information 31a includes information indicating the history of maintenance performed on the unit U of the component mounting equipment M2 to M5 (production equipment) that is detachably attached to the production circuit board (product).

[0047] exist Figure 3In this process, the collection unit 32 collects production records from each production device on the assembly lines L1 to L3 and stores these production records as record information 31b in the management storage unit 31. Record information 31b includes information specifying the unit U attached to the component assembly devices M2 to M5, the number of times the unit U is used, the operation time of the component assembly devices M2 to M5 in operating to produce circuit boards, the number of circuit boards produced by the component assembly devices M2 to M5, and information about operational errors. Here, the number of times the unit U is used can be the number of times the unit U is used within a predetermined period immediately preceding the current time point, or it can be the total number of times the unit U is used up to the current time point (hereinafter also referred to as "total usage"). Information about operational errors includes the time when the operational error occurred, the content of the operational error, and information specifying the unit U associated with the operational error.

[0048] As described above, the record information 31b includes production records when the unit U is attached to any of the component mounting devices M2 to M5 (production equipment) included in the multiple mounting lines L1 to L3 and used to produce circuit boards.

[0049] exist Figure 3 In the process, designated unit 33 obtains historical information 31a, and designates unit U to perform maintenance based on the maintenance date and time included in the historical information 31a.

[0050] exist Figure 3 In this process, the acquisition unit 34 acquires record information 31b indicating production records performed on unit U after maintenance, for multiple maintenance operations performed on unit U as specified by the designation unit 33. For example, the acquisition unit 34 acquires information about at least one of a work error that occurred within a predetermined period after maintenance and the output values ​​of a sensor measured within that predetermined period.

[0051] More specifically, the acquisition unit 34 acquires at least one of the error rate (hereinafter referred to as "error rate R") of unit U during a predetermined period after maintenance and the output value of the sensor (hereinafter referred to as "sensor value S") during the predetermined period after maintenance. As described above, the error rate R and sensor value S associated with unit U are examples of record information 31b indicating the production records of unit U after maintenance.

[0052] exist Figure 3 In this process, the acquisition unit 34 also acquires the number of times the unit U was used within a predetermined period after maintenance (hereinafter also referred to as the "number of times used after maintenance" record value). Therefore, the acquired number of times the unit U was used after maintenance is an example of the record information 31b of the production record indicating the use of the unit U after maintenance.

[0053] Here, the scheduled period after maintenance is the time from the point when production begins using unit U after its maintenance until the next maintenance is performed. This scheduled period is, for example, the time after unit U is attached to component mounting equipment M2 to M5 after maintenance, such as two days.

[0054] exist Figure 3 In this process, prediction unit 35 performs a process of predicting the time during which unit U cannot be used for production even after maintenance. For example, prediction unit 35 predicts a usage limit time or usage limit count based on historical information 31a or recorded information 31b. The usage limit time is the time during which unit U cannot be used for production even after maintenance, and the usage limit count is the number of times unit U can be used until the time during which unit U cannot be used for production even after maintenance. For example, the usage limit time is the time when the number of times unit U is used reaches the usage limit count.

[0055] Furthermore, prediction unit 35 predicts the time when unit U needs to be replaced with a candidate unit based on usage limit time or usage limit count (predicting replacement time). For example, the candidate unit is a unit of the same type as unit U.

[0056] Here, the usage limit time is any one of the following: the time when unit U fails, the time when unit U fails to return to the predetermined state (predetermined sensor value S, etc.) even after maintenance is performed, and the time when the predetermined expiration date (hypothetical expiration date) is reached. Furthermore, the usage limit count is any one of the following: the number of times unit U can be used until unit U fails, the number of times unit U can be used at least until it fails to return to the predetermined state (predetermined sensor value S, etc.) even after maintenance is performed, and the number of times unit U reaches the predetermined number of uses (hypothetical number of uses Ct). In the following text, the usage limit time or usage limit count is simply referred to as "usage limit".

[0057] exist Figure 3 Specifically, prediction unit 35 predicts usage limits (usage limit time, usage limit count) based on trends in at least one of the following: the error rate R associated with unit U within a predetermined period after maintenance, the maintenance interval of unit U, and the number of times unit U is used after maintenance. For example, the maintenance interval of unit U is calculated based on at least one of the recorded value of the number of times unit U is used after maintenance included in record information 31b and the date and time of unit U maintenance included in historical information 31a.

[0058] Furthermore, the recorded number of times unit U has been used after maintenance is the number of times unit U has been used up to the current time point, but may include the predicted number of times unit U will be used until production is completed if unit U continues to be used to produce circuit boards after the current time point. More specifically, the recorded number of times unit U has been used after maintenance can be calculated by adding the number of times unit U has been used from the production start time point from the time point when production begins after maintenance to the current time point to the remaining number of uses. The remaining number of uses is calculated by multiplying the number of components on each board installed using unit U by the remaining production quantity.

[0059] Next, we will refer to Figure 4 and Figure 5 The description is based on the prediction using limit counting by prediction unit 35. Figure 4 This is a diagram illustrating an example of the configuration of unit information generated in an installation system according to an embodiment of the present disclosure. Figure 5 This diagram illustrates the prediction of usage limit counts based on sensor values ​​after maintenance in an installation system according to an embodiment of the present disclosure. The usage limit time is predicted by the prediction unit 35, which, in addition to calculating the usage limit count, also performs a process of calculating the time to reach the usage limit count.

[0060] exist Figure 4 In this example, the total number of uses C7 is an example of the usage limit count predicted by the prediction unit 35. The feeder 10 is an example of the unit U.

[0061] exist Figure 5 In this context, when maintenance is performed on the feeder 10 with a total number of uses C4, the sensor value S obtained by measuring the feeder 10 via a sensor is "S4". The sensor value S "S4" is a value lower than a first sensor threshold St1. For example, the first sensor threshold St1 is a threshold used to determine whether maintenance related to the feeder 10 is required. That is, it means that the feeder 10 with a total number of uses C4 is in a normal state due to maintenance.

[0062] The prediction unit 35 calculates the number of times the feeder 10 can be used for production after the time point C4 of the total number of uses. In other words, the prediction unit 35 calculates "C5-C4" as the number of times the feeder 10 can be used in normal condition. If maintenance is performed on the feeder 10 at the time point C5 of the total number of uses, the prediction unit 35 calculates "C6-C5" as the number of times the feeder 10 can be used in normal condition.

[0063] As described above, prediction unit 35 calculates the number of times unit U can be used after maintenance for the planned maintenance of unit U (hereinafter also referred to as the predicted value of "number of times used after maintenance").

[0064] As described above, prediction unit 35 calculates a predicted number of times unit U will be used after maintenance, and calculates a usage limit count. For example, prediction unit 35 calculates a usage limit count of unit U based on the number of times unit U can be used under normal conditions. More specifically, the usage limit count is calculated by adding the cumulative number of times unit U has been used up to the current time point to the predicted number of times it will be used after maintenance.

[0065] The usage limit can be any metric generated from the usage limit count, and can be, for example, the remaining time until maintenance unit U cannot be used for production, or the remaining number obtained by subtracting the number of times unit U has been used up to the current time point from the usage limit count of unit U. Figure 4 and Figure 5 The example described above is that the usage limit count predicted by prediction unit 35 is the total number of uses C7, but the usage limit count can be any number that is equal to or greater than the total number of uses C6 and less than the total number of uses C7.

[0066] exist Figure 3 In the process, output unit 36 ​​outputs to unit information 31c the total number of times a specified unit U is used, the error rate R and sensor value S obtained by acquisition unit 34, the recorded number of uses after maintenance, the usage limits (usage limit time, usage limit count) predicted by prediction unit 35, and the predicted replacement time. Based on the predicted usage limits (usage limit time, usage limit count), output unit 36 ​​outputs to unit information 31c information indicating units U that are estimated to require alternative units. Based on the predicted replacement time of each unit U, output unit 36 ​​specifies and outputs units U that reach their predicted replacement time within a predetermined time period.

[0067] Here, we will refer again Figure 4 Example describing the unit information 31c of feeder 10. Unit information 31c, for each total usage 50 during maintenance, includes the number of uses 51 after maintenance, the sensor value 52 after maintenance, the error rate 53 after maintenance, and the predicted replacement time 54. The total usage 50 of feeder 10 is the sum of the number of times feeder 10 supplies component D to component supply location 10a. The number of uses 51 after maintenance, the sensor value 52 after maintenance, and the error rate 53 after maintenance for total usage 50 from "0" to "C4" are recorded values. The number of uses 51 after maintenance, the sensor value 52 after maintenance, and the error rate 53 after maintenance for total usage 50 from "C5" to "C7" are predicted values.

[0068] When the total number of uses 50 is "C4" (hereinafter referred to as "total number of uses C4", etc.), the number of uses 51 after maintenance is "C4-C3", the sensor value 52 after maintenance of the sensors included in the feeder 10 is "S4", and the error rate (failure rate) 53 after maintenance (which is the supply error of the feeder 10 that occurs within a predetermined period after maintenance) is "R4". At the point in time of total number of uses C4, the predicted replacement time 54 of the feeder 10 is "one year later".

[0069] Next, we will refer to again Figure 5 Description based on Figure 4 The recorded value of sensor 52 after maintenance of the feeder 10 is used to predict the limit count. Figure 5 This is an XY graph, where the total number of uses C is plotted on the horizontal axis, and the sensor values ​​S of the sensors included in the feeder 10 are plotted on the vertical axis. In this example, a smaller sensor value S indicates a better state of the feeder 10, and a larger sensor value S indicates a worse state of the feeder 10.

[0070] exist Figure 5 In the diagram, the vertical axis indicates the first sensor threshold St1 and the second sensor threshold St2. When the sensor value S reaches the first sensor threshold St1, maintenance is determined to be required, and a maintenance plan is created to perform maintenance on the feeder 10 before the sensor value S exceeds the second sensor threshold St2. When the sensor value S exceeds the second sensor threshold St2, the feeder 10 cannot be used for production.

[0071] As described above, the sensor value S is the measurement result of the sensor installed in unit U. Typically, as the recorded number of times unit U is used increases after maintenance, the state of unit U changes in the following order: normal state, warning state before an abnormal state, and abnormal state. A sensor value S less than the first sensor threshold St1 is an example of unit U being in a normal state.

[0072] exist Figure 5 In this embodiment, a sensor value S greater than or equal to a first sensor threshold St1 and less than a second sensor threshold St2 is an example of a state where the unit U is in a premonition state. A sensor value S exceeding the second sensor threshold St2 is an example of an abnormal state of the unit U. In this embodiment, the prediction unit 35 predicts the time during which the state of the unit U will not return to a normal state even after maintenance. In other words, the prediction unit 35 predicts the number of times the unit U can be used until it fails to return to a normal state even after maintenance, using a limit count.

[0073] exist Figure 5In the diagram, the sensor value S0 before maintenance (total usage count of 0) is linearly connected to the sensor values ​​S1, S2, S3, and S4 (recorded values) before and after maintenance at the time points C1, C2, C3, and C4 (total usage counts). As the total usage count C increases, the sensor value S after maintenance tends to gradually deteriorate and cannot be restored to the previously maintained state. Furthermore, the number of uses until the sensor value S reaches the first sensor threshold St1 after maintenance (51 uses after maintenance) also tends to gradually decrease. That is, the maintenance interval tends to shorten.

[0074] Prediction unit 35 predicts the total number of uses C5, C6, and C7 at the next maintenance, and the sensor values ​​S5, S6, and S7 after maintenance, based on the number of uses 51 (maintenance interval) after maintenance and the degree of recovery of the sensor value S after maintenance. In this example, it is predicted that even if maintenance is performed at the time point when the number of uses of feeder 10 reaches a total number of uses C7 that is smaller than the assumed number of uses Ct, feeder 10 will not recover to its normal state (see also...). Figure 4 ).

[0075] exist Figure 4 In this configuration, the predicted replacement time 54 (which is the time for replacement with an alternative unit) is set to the point in time when the feeder 10 reaches its usage limit count. That is, the predicted replacement time 54 is set to the usage limit time. Preferably, the replacement with an alternative unit is performed with a margin before the feeder 10 reaches its total usage count C7, and the predicted replacement time 54 can be set at the point in time when the total usage count C5 or C6 is reached. Alternatively, the predicted replacement time 54 can be set to a time period when the feeder 10 is not used for production, based on the production plan.

[0076] exist Figure 3 In the process, the display processing unit 37 causes the display unit 39 to display a unit replacement information display screen based on the unit information 31c. The unit replacement information display screen is used to display information related to the unit U that needs to be replaced within a predetermined time period.

[0077] Next, we will refer to Figure 6 This describes an example of a unit replacement information display screen 60 displayed on a display unit 39 by a display processing unit 37. Figure 6This is a diagram illustrating an example of a unit replacement information display screen shown on a display unit included in a management computer according to an embodiment of the present disclosure. The unit replacement information display screen 60 includes a unit name selection box 61, a replacement time selection box 62, and a unit information display box 63. In the unit name selection box 61, the type of unit U to be displayed in the unit information display box 63 is selected by operating the input unit 38. In this example, "feeder" is selected. In the replacement time selection box 62, the replacement time of the unit U to be displayed in the unit information display box 63 is selected by operating the input unit 38. In this example, "within 6 months" is selected.

[0078] The unit information display box 63 displays the unit name selected in the unit name selection box 61 and information about the unit U that matches the replacement time selected in the replacement time selection box 62. In this example, it displays the unit number, start time of use, predicted failure time, and replacement time for "feeders with a replacement time within six months". The unit number is the information used to specify unit U. The start time of use is the time when unit U begins to be used in production. The predicted failure time is the time when unit U is predicted to fail. The replacement time is the predicted replacement time 54 included in the unit information 31c.

[0079] Production administrators can easily determine the replacement timing of unit U based on the information displayed on the unit replacement information display screen 60, and can purchase the required unit U at the appropriate time. Therefore, production stoppages due to unit U failures or excessive inventory of unit U can be prevented.

[0080] Next, we will follow Figure 7 The process description describes the unit management method of the unit U that is detachably attached to the production equipment by the installation system 1 (unit management system). Figure 7 This is a flowchart illustrating a unit management method according to an embodiment of the present disclosure. The collection unit 32 appropriately collects historical information 31a from the maintenance support equipment 4, collects production records from each production device on the installation lines L1 to L3, and stores the production records as record information 31b in the management storage unit 31.

[0081] First, the designated unit 33 determines whether the collection unit 32 updates the historical information 31a, i.e., whether maintenance is performed on unit U (ST1: Determination step). When maintenance is performed ("Yes" in ST1), the designated unit 33 acquires the historical information 31a indicating the maintenance performed on unit U (ST2: Historical information acquisition step). Next, the designated unit 33 designates the unit U that has undergone maintenance based on the acquired historical information 31a (ST3: Designation step). Next, the acquisition unit 34 acquires record information 31b indicating the production records of unit U used after maintenance for the multiple maintenance performed on the designated unit U (ST4: Record information acquisition step).

[0082] exist Figure 7 Next, based on historical information 31a or recorded information 31b, prediction unit 35 predicts the usage limit time that unit U cannot be used for production even after maintenance, or the usage limit count until the unit cannot be used for production even after maintenance (ST5: Usage Limit Prediction Step). Next, output unit 36 ​​outputs information indicating the unit U that is estimated to require a replacement unit (predicted replacement time 54, etc.) to unit information 31c based on the predicted usage limits (usage limit time, usage limit count) (ST6: Output Step). Therefore, the unit U that requires a replacement unit and the replacement time can be easily determined, and the units U that need maintenance can be appropriately managed.

[0083] As described above, the management computer 3 according to this embodiment is a unit management system, which includes: a designation unit 33, which acquires maintenance history information 31a and designates units U that have been maintained; an acquisition unit 34, which acquires record information 31b indicating production records of units U after maintenance for multiple maintenance performed on the designated units U; a prediction unit 35, which predicts the usage limit (usage limit time, usage limit count) of units U that cannot be used for production even if maintenance is performed, based on at least one of the history information 31a and the record information 31b; and an output unit 36, which outputs information (unit information 31c) indicating units U that are estimated to be candidate units based on the predicted usage limit.

[0084] Therefore, the units U that require maintenance can be managed appropriately.

[0085] In the aforementioned unit management system, the management computer 3 possesses all the functions of a storage unit and a processing unit, but the unit management system is not limited to this configuration. For example, a production line management computer including a collection unit 32 can be set up for each of the installation lines L1 to L3, which collects record information 31b, including the error rate R, from the production equipment. The designation unit 33, the acquisition unit 34, and the prediction unit 35 can be included in a different computer than the management computer 3. All or some of the functions of the management computer 3 can be implemented in the cloud.

[0086] The maintenance support device 4 can be configured to acquire sensor values ​​S measured by sensors included in unit U as record information 31b, and send the sensor values ​​S to the management computer 3. Furthermore, the management computer 3 can be configured to cause the prediction unit 35 to predict the usage limit time or usage limit count based on the sensor values ​​S associated with unit U after a predetermined period has elapsed since maintenance.

[0087] In this embodiment, an example has been described where the recorded information 31b includes measurement results (sensor values ​​S) from sensors disposed in the unit U. However, the recorded information 31b may include state information indicating the state of the unit U determined based on the measurement results. For example, the state of the unit U may include a state of performance degradation, a normal state, a warning state before the unit U becomes abnormal, or an abnormal state.

[0088] In this embodiment, an example has been described whereby the prediction unit 35 predicts the usage limit based on the sensor value S obtained by the measurement unit U. However, the prediction unit 35 may also predict the usage limit based on the state information of the unit U, in addition to or replacing the sensor value S obtained by the measurement unit U. For example, if maintenance is performed on the unit U before its state becomes abnormal, the prediction unit 35 may predict the time or number of times the unit U's state becomes abnormal even after the maintenance as the usage limit.

[0089] Furthermore, in this embodiment, an example has been described of the predicted number of uses after maintenance as the number of times unit U can be used when the sensor value S is below the first sensor threshold St1. However, the predicted value can also be the number of times unit U can be used when the sensor value S is below the second sensor threshold St2. That is, the prediction unit 35 can predict the usage limit of unit U by calculating the number of times unit U can be used in the premonition state.

[0090] Furthermore, an example has been described in which the prediction unit 35 of this embodiment predicts the usage limit based on the number of times the unit U is used after maintenance, but the usage limit can also be predicted based on the time the unit U is used for production within a predetermined period after maintenance.

[0091] Prediction unit 35 can predict usage limits based on recorded values ​​of the number of times unit U is used for each state associated with unit U. In other words, the recorded values ​​of the number of times unit U is used after maintenance can include the number of times unit U is used in the normal state within a predetermined period after maintenance and / or the number of times unit U is used in the premonition state after maintenance.

[0092] Furthermore, in this embodiment, an example has been described where the sensor value S is measured by a sensor included in the unit U, but the sensor may be included in at least one of a production device to which the unit U is attached and a maintenance support device for performing maintenance on the unit U.

[0093] In the above description, the component mounting equipment M2 to M5 used in the mounting lines L1 to L3 for producing circuit boards (products) has been described as examples of production equipment with attached units U, but the production equipment is not limited to this. For example, the production equipment may be the printing equipment M1, the reflow equipment M6, or the inspection equipment included in the mounting lines L1 to L3. In this case, an example of the management computer 3 obtaining the recording information 31b in the component mounting equipment M2 to M5 according to this embodiment has been described, but the management computer 3 may also obtain the recording information 31b in the production equipment (which is not the mounting equipment constituting the mounting lines L1 to L3).

[0094] In addition, production equipment can be production equipment set up in a semiconductor manufacturing production line for manufacturing semiconductor products, production equipment set up in an assembly production line for assembling workpieces such as electrical mechanical tools or general mechanical tools, or production equipment set up in a food processing line for producing food processed products.

[0095] This application is based on Japanese patent application filed on March 29, 2024 (Japanese Patent Application No. 2024-056937), the contents of which are incorporated herein by reference.

[0096] Industrial applicability

[0097] The cell management system and cell management method disclosed herein have the effect of properly managing cells that require maintenance, and are useful in the field of mounting components on a substrate.

[0098] List of reference numerals

[0099] 1. Install the system (unit management system)

[0100] 3. Management computer (unit management device)

[0101] L1 to L3 installation line

[0102] M2 to M5 component installation equipment (production equipment)

[0103] 10 Feeders (Units)

[0104] 13 nozzles (units)

[0105] 14 Head (Unit)

[0106] 16-component recognition camera (unit)

[0107] 17 head cameras (units)

[0108] U unit

[0109] R error rate

[0110] Sensor values ​​(measurement results) from S0 to S7.

Claims

1. A unit management system, comprising: A designated unit is configured to acquire historical information indicating the history of maintenance performed on a unit of a production equipment that can be detachably attached to a production product, and to designate the unit for which maintenance has been performed. The acquisition unit is configured to acquire record information indicating the use of the production record of the unit after maintenance for multiple maintenance operations performed on the specified unit; The prediction unit is configured to predict, based on at least one of the historical information and the record information, the usage limit time when the unit cannot be used for production even after maintenance, or to predict the usage limit count indicating the number of uses until the unit cannot be used for production even after maintenance. as well as The output unit is configured to output information about the unit that is estimated to be a candidate unit based on the predicted usage limit time or the predicted usage limit count.

2. The unit management system according to claim 1, wherein, The usage limit time is any one of the following: the time when the unit fails, the time when the unit fails to return to the predetermined state even after maintenance, and the time when the predetermined expiration date is reached.

3. The unit management system according to claim 1, wherein, The usage limit count is any one of the following: the number of times the unit can be used until the unit fails, the number of times the unit can be used until the unit is not restored to the predetermined state even after maintenance, and the number of times the unit reaches the predetermined number of uses.

4. The unit management system according to claim 1, wherein, The prediction unit predicts the usage limit time or the usage limit count based on a trend of at least one of the production records within a predetermined period after maintenance, the maintenance interval of the unit, and the number of times the unit is used between maintenance periods.

5. The unit management system according to claim 1, wherein, The recorded information includes any one of the following: information about the error rate associated with the unit, measurement results from sensors installed in the unit, and an anomaly degree determined based on the measurement results, the anomaly degree indicating an abnormal state or a precursory state of the unit.

6. The unit management system according to claim 1, wherein, The unit is at least one of a nozzle, feeder, and head of a production equipment included in the mounting line attached to the production circuit board, and The recorded information includes production records when the unit is attached to any of the production equipment included in a plurality of mounting lines and used to produce the circuit board.

7. A unit management method, comprising: Obtain historical information indicating the maintenance performed on units of production equipment that can be detachably attached to the production product; Based on the historical information, specify the units that have already undergone maintenance; For multiple maintenance operations performed on a specified unit, obtain record information indicating the use of the unit's production records after maintenance; Based on at least one of the historical information and the recorded information, predict the usage limit time when the unit cannot be used for production even after maintenance, or predict the usage limit count indicating the number of uses until the unit cannot be used for production even after maintenance; and Based on the predicted usage limit time or the predicted usage limit count, the output indicates information about the cells that are estimated to require alternative cells.

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