Production management device

Abstract

A manufacturing management device comprises: a calculation section configured to calculate a failure rate of a mounting operation for mounting a component supplied from a component supply unit onto a circuit board, wherein a component receiving member is replaceably inserted in a component mounter, for each predetermined period divided according to a time including at least a replacement time of the component receiving member, after repeatedly performing the mounting operation; and an estimation section configured to determine, by estimation, whether the component supply unit and / or the component receiving member have a failure cause based on the failure rate for each predetermined period.

Description

Technical area

[0001] The present description relates to a production management apparatus for a component mounter that performs a component mounting operation using a component feed unit. State of the art

[0002] A technique for mass-producing printed circuit board products by performing multi-step manufacturing operations on a printed circuit board on which a circuit pattern is formed has been widely adopted. A representative example of a printed circuit board manufacturing equipment that performs manufacturing is a component mounter that performs a mounting operation in which a component is mounted on a printed circuit board. Generally, a component mounter feeds a component using a component feeder in which a component receiving member is replaceably inserted, and causes the component mounting tool to perform a mounting operation. In this type of component mounter, a failure resulting in an erroneous mounting operation rarely occurs. A cause of a failure may lie in various places, such as the component feeder, the component mounter, or the data used for the mounting operation.By performing appropriate maintenance according to an increase in the defect rate or the cause of the defect, it is possible to maintain good production efficiency of the component mounter. An example of a technique for estimating the cause of the defect occurring in the component mounter is disclosed in Patent Literature 1.

[0003] The mounting error cause estimation device disclosed in Patent Literature 1 selects a first factor and a second factor from devices and data that may cause a mounting error, determines whether a failure occurrence situation obtained for each individual device of the second factor deviates under a condition in which the first factor is specified, determines whether a failure occurrence situation obtained for each individual device of the first factor deviates under a condition in which the second factor is specified, and estimates a causal individual device with respect to the increasing error based on the two determination results. Thus, it is possible to estimate the causal individual device with higher reliability than in the conventional art based on multiple determination results. List of cited publicationsPatent literature

[0004] Patent literature 1: WO 2020 / 188774 Overview of the inventionTechnical problem

[0005] When Patent Literature 1 considers the component feed unit (device) as the individual equipment causing the problem, it cannot distinguish whether the component feed unit device itself is the cause or the component receiving element contained therein. If the cause cannot be accurately determined, proper maintenance becomes difficult. As a result, the increased defect rate is not improved, or the burden on personnel is unnecessarily increased by performing unnecessary maintenance work.

[0006] Therefore, it is an object of the present description to provide a production management device capable of estimating whether a component feeding unit or a component receiving element is the cause of a failure. Solution to the problem

[0007] The present description discloses a manufacturing management device comprising: a calculation section configured to calculate a failure rate of a mounting process for mounting a component provided by a component supply unit on a circuit board, wherein a component receiving member is replaceably inserted in a component mounter for each predetermined period divided according to a time including at least a replacement time of the component receiving member after repeated execution of the mounting process; and an estimation section configured to determine, by estimation, whether the component supply unit and / or the component receiving member is / are a cause of failure based on the failure rate for each predetermined period.

[0008] The present specification discloses a technical idea in which "the production management device according to any one of claims 1 to 3" in claim 6 as originally filed is changed to "the production management device according to any one of claims 1 to 5", a technical idea in which "the production management device according to any one of claims 1 to 3" in claim 7 as originally filed is changed to "the production management device according to any one of claims 1 to 6", a technical idea in which "the production management device according to any one of claims 1 to 3" is changed to "the production management device according to any one of claims 1 to 7" in claim 8 as originally filed, and a technical ideain which "the production management device according to any one of claims 1 to 3" is changed to "the production management device according to any one of claims 1 to 9" in claim 10 in the originally filed version. Advantageous effects of the invention

[0009] In the manufacturing management apparatus disclosed in the present specification, since the calculation section calculates the failure rate for each predetermined period divided before and after the replacement time of the component receiving member, the estimation section can estimate whether the component feeding unit or the component receiving member is the cause of the failure based on the difference in the failure rate before and after the replacement time. Short description of the drawings Fig. 1 is a plan view schematically illustrating an overall structure of a component mounter incorporating a production management apparatus of a first embodiment. Fig. 2 is a side view schematically illustrating a structure of a tape feeder which is one form of a component feeding unit. Fig. 3 is a functional flowchart illustrating the function of the manufacturing management device. Fig. 4 is a diagram of a first example illustrating a temporal transition of a defect rate, and illustrating a case where the component feeding unit (tape feeder) is a cause. Fig. 5 is a graph of a second example illustrating the time transition of the defect rate, and illustrating a case where the component receiving element (reel or carrier tape) is the cause. Fig. 6 is a table illustrating an estimation process of an estimation section. Fig. 7 is a diagram schematically illustrating a manufacturing management apparatus of a second embodiment. Fig. 8 is an operational flowchart illustrating the operation of the manufacturing management apparatus of the second embodiment. Fig. 9 is a diagram of a third example illustrating the temporal transition of the error rate, and illustrates a case where a setting of a predetermined period differs from the first embodiment and a temporary stop control section is in operation. Description of embodiments 1. Example of a component placement machine 1

[0010] First, an overall structure of the component mounter 1 in which a production management device 7 of a first embodiment is integrated will be described with reference to Fig. 1. The component mounter 1 repeatedly performs a mounting operation for mounting a component on a circuit board K. A horizontal direction from a left side to a right side in the drawing plane in Fig. 1, in which the printed circuit board K is conveyed, is an X-axis direction, a horizontal direction from a lower side (front side) to an upper side (back side) in the plane of the drawing is a Y-axis direction, and a vertical direction is a Z-axis direction. The component mounter 1 is provided on a base 10 with a mounting board conveying device 2, a component feeding device 3, a component transfer device 4, and a control device 5, and the like.

[0011] The printed circuit board conveying device 2 includes two guide rails 21 provided as a pair, two conveyor belts (not shown), a clamping mechanism (not shown), and the like. The two guide rails 21 extend in the X-axis direction beyond a slightly rear side of an upper surface of the base 10 and are mounted parallel to each other on the base 10. The two conveyor belts rotate along the guide rails 21 in a state where two parallel sides of the printed circuit board K are aligned, and they convey the printed circuit board K to a stop position near the center of the base 10. The clamping mechanism pushes the conveyed printed circuit board K upward, clamps the printed circuit board K between the guide rails 21, and positions the printed circuit board K.After completion of the assembly process by the component transfer device 4, the clamping mechanism releases the circuit board K and the conveyor belts transport the circuit board K out of the device.

[0012] The component feeder 3 includes a pallet table 31 and a plurality of tape feeders 6. The pallet table 31 is a substantially rectangular member in plan view and has a plurality of slots arranged in the X-axis direction while extending parallel to each other in the Y-axis direction. The tape feeder 6 is detachably inserted into and fixed to a plurality of slots. The tape feeder 6 is a form of component feeding unit that feeds a component using an interchangeably inserted component receiving member. In the tape feeder 6, a carrier tape CT holding a plurality of components and a reel RL on which the carrier tape CT is wound are interchangeably inserted. The tape feeder 6 feeds the carrier tape CT to the feed position 65 set at the rear upper portion to feed the components (details will be described below).

[0013] The component transfer device 4 includes two guide rails 40 provided as a pair, a Y-axis moving body 41, an X-axis moving body 42, a mounting head 43, a nozzle tool 44, a suction nozzle 45, a board detection camera 46, a component detection camera 47, and the like. The two guide rails 40 are arranged at both edges of the base 10, separated from each other in the X-axis direction, and extend parallel to each other in the Y-axis direction. The Y-axis moving body 41 is formed from a member elongated with respect to the X-axis direction and mounted on the two guide rails 40. The Y-axis moving body 41 is driven by a Y-direction drive mechanism (not shown) to move in the Y-axis direction.The X-axis moving body 42 is mounted on the Y-axis moving body 41 and is driven by an X-direction drive mechanism (not shown) to move in the X-axis direction.

[0014] The mounting head 43 is provided on a front side of the X-axis moving body 42 and arranged above the circuit board conveying device 2 and the component feeding device 3. The mounting head 43 moves together with the X-axis moving body 42 in two horizontal directions. The nozzle tool 44 with a rotationally symmetrical shape is rotatably mounted on the bottom of the mounting head 43. The nozzle tool 44 is driven by an R-axis drive mechanism (not shown) for rotation about a vertical central axis. The nozzle tool 44 has a plurality of (in the example of Fig. 1 four) suction nozzles 45 are provided at equal intervals from the vertical center axis. The suction nozzle 45 is driven to move up and down by a lifting and lowering drive mechanism (not shown) and is driven to rotate around a vertical axis by a Q-axis drive mechanism (not shown). In addition, the suction nozzle 45 is selectively supplied with negative pressure air and positive pressure air from an air supply mechanism (not shown). Accordingly, the suction nozzle 45 performs the mounting process for mounting the component on the circuit board K by picking up the component from the component feeder 3. In the mounting head 43, one suction nozzle 45 may be provided without a nozzle tool 44, or a plurality of suction nozzles 45 may be arranged in a row or in a grid pattern.

[0015] The board detection camera 46 is mounted on the body 42 moving along the X-axis, next to the mounting head 43, and faces downward. The board detection camera 46 captures a position reference mark attached to the board K from above. The captured image data is subjected to image processing so that the stop position of the board K is accurately determined. The component detection camera 47 is mounted on the base 10 between the board conveying device 2 and the component feeding device 3 and faces upward. The component detection camera 47 captures the component held by the suction nozzle 45 from below and detects the component while the mounting head 43 moves from the component feeding device 3 to the board K. This determines whether the component type is correct or incorrect, and the position and orientation of the component with respect to the suction nozzle 45 are detected and taken into account during mounting.Examples of a circuit board recognition camera 46 and a component recognition camera 47 include a digital imaging device having an imaging element such as a charge-coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS).

[0016] The control device 5 is mounted on the base 10, and its position is not limited. The control device 5 includes a computer device with a CPU that operates with software. The control device 5 may be configured such that multiple CPUs are distributed and arranged in the device and communicate with each other. The control device 5 includes an input section (not shown) that receives a command, selection, and the like from the operator, and a display section (not shown) that transmits various information to the operator.

[0017] The control device 5 receives mounting order data 51 from the higher-level management device (not shown) and stores (holds) the mounting order data 51 in a connected memory 52. ​​The mounting order data 51 is data used for the mounting process and is created for each type of printed circuit board product (printed circuit board K). The mounting order data 51 includes shape data for each type of printed circuit board K, shape data for each type of component, mounting coordinate data for the component, data regarding the tape feeder 6 and the suction nozzle 45 to be used, and detailed process data for the mounting process. The control device 5 causes the printed circuit board conveying device 2, the component feeding device 3, and the component transfer device 4 to proceed with the mounting process based on the mounting order data 51. 2. Structure of the belt feed 6

[0018] Next, a structure of the tape feeder 6 will be described in detail with reference to Fig. 2. The tape feeder 6 includes a main body 61, a tape feed mechanism 66, and a feed control section 69. The main body 61 is primarily formed of a side plate elongated in the front-to-back direction. The main body 61 includes a detachable rail 62, a roll support shaft 63, a guide rail 64, and a peel-off mechanism (not shown).

[0019] The detachable rail 62 is provided on the bottom of the main body 61 and extends in the Y-axis direction. The detachable rail 62 is inserted into the slot of the pallet table 31, thereby attaching the tape feeder 6 thereto. The roll support shaft 63 is provided at a position toward the lower front side of the main body 61 and extends in the X-axis direction. The roll support shaft 63 rotatably and replaceably supports the center hole of the roll RL on which the carrier tape CT is wound. A label LB indicating the individual information for the roll RL and the type information of the component is affixed to the side surface of the roll RL. Replacing a used roll RL on which there is no more carrier tape CT with another roll RL can be performed either with the tape feeder 6 mounted or detached.

[0020] The carrier tape CT comprises a base tape and a cover tape. Cavities for receiving components are formed in the base tape at a constant spacing along the tape's length. The cover tape is attached to the base tape by two adhesive strips extending in the tape's length. The cover tape covers the cavities and prevents the components from falling out. Several feed holes are provided at a constant spacing along one side edge of the carrier tape CT.

[0021] The guide rail 64 starts from a position diagonally upward on the back of the roll support shaft 63, extends diagonally upward to the back, changes into a horizontal extension to the back from the center, and ends at the upper rear end portion of the main body 61. A position near the end point of the guide rail 64 becomes the feeding position 65. The guide rail 64 guides the carrier tape CT fed from the roll RL to the feeding position 65. The peeling mechanism (not shown) is located in the center of the guide rail 64. The peeling mechanism peels the cover tape from the base tape to open the cavities and allows the suction nozzle 45 to pick up the components.

[0022] The tape feed mechanism 66 feeds the carrier tape CT at a constant pitch and sequentially delivers a plurality of components to the feed position 65. The tape feed mechanism 66 includes a sprocket 67, a drive motor 68, and a gear mechanism (not shown). The sprocket 67 is disposed at a position diagonally downward on the front side with respect to the feed position 65 and is rotatably supported by the main body 61. The upper part of the sprocket 67 passes through a groove formed in the guide rail 64 and projects upward. The teeth on the outer periphery of the sprocket 67 engage with the feed holes of the carrier tape CT.

[0023] The drive motor 68 rotates the sprocket 67 via the gear mechanism. A stepper motor, for example, is used as the drive motor 68, and the drive motor 68 can intermittently drive the sprocket 67 at a constant angle. Accordingly, the carrier tape CT can be fed at a constant pitch. The drive motor 68 is capable of reverse rotation, allowing the carrier tape CT to be rewound. Furthermore, the drive motor 68 can be operated for a longer time than with intermittent drive, allowing longer feeding of the carrier tape CT at the beginning of operation and longer rewinding at the end of operation.

[0024] The feed control section 69 is provided in the main body 61, and its location is not limited. The feed control section 69 is a computer device operated by software. The feed control section 69 controls the drive motor 68. The feed control section 69 is connected to a connector 6A, a tape detection sensor 6B, and an operation panel 6C. The connector 6A is located on the rear side of the main body 61. When the tape feeder 6 is attached to the pallet table 31, the connector 6A is automatically connected to a take-up side connector (not shown) of the pallet table 31. Accordingly, the tape feeder 6 is supplied with power. Furthermore, the feed control section 69 is connected to the control device 5 and continues the control operation according to a command from the control device 5.

[0025] The tape detection sensor 6B is arranged on an inclined portion near the starting point of the guide rail 64. The tape detection sensor 6B detects the presence or absence of the carrier tape CT to be fed and outputs a detection signal to the feed control section 69. The operation panel 6C is arranged at the front end of the upper surface of the main body 61. The operation panel 6C has a mode switch 6D, a feed switch 6E, and a display section (not shown). The mode switch 6D is a manual switch that switches between several operation modes of the feed control section 69, such as the operation mode and the setting mode. The feed switch 6E is a manual switch for feeding and winding the carrier tape CT. The display section is a part that displays the current operation mode, the operation state, the presence or absence of abnormalities, and the like, and is provided with, for example, several indicator lamps.

[0026] The tape feeder 6 may be of a type that does not hold the roll RL in the main body 61, but feeds the carrier tape CT from the roll RL held in a separately provided roll holder. Furthermore, a component feeding unit other than the tape feeder 6, such as a tray feeder using a tray in which a plurality of components are accommodated in a two-dimensional lattice shape, or a rod feeder using a cylindrical rod that accommodates a plurality of components in a row, may be detachably mounted on the pallet table 31. That is, the component receiving member may be a tray or a rod.

[0027] 3. Structure of the Production Management Device 7 of the First Embodiment The following is a description of the production management device 7 of the first embodiment. As shown in Fig. As shown in FIG. 1, the production management device 7 is configured within the control device 5, that is, it is configured using software of the control device 5. The production management device 7 may be implemented using a computer device other than the control device 5. The production management device 7 includes a calculation section 71, an estimation section 72, and an instruction section 73.

[0028] The calculation section 71 calculates the failure rate E of the mounting process after the mounting process for mounting the components supplied from the tape feeder 6 onto the circuit board K in the component mounter 1 has been repeatedly performed. Specifically, the calculation section 71 calculates the failure rate E for each predetermined period divided according to a time including at least the replacement time of the tape feeder 6. This predetermined period is set using a period including a predetermined frequency Ns of the mounting process. This predetermined period can be reformulated as a period required for the mounting process of a number of components equal to the predetermined frequency Ns.The calculation section 71 counts the number of errors Ne in which the mounting operations failed over the predetermined period of time, and calculates the error rate E by dividing the number of errors Ne by the predetermined frequency Ns.

[0029] Furthermore, when the predetermined number of times Ns of the mounting operations are divided according to the replacement time for the roll RL and the carrier tape CT, so that a partial frequency Nh occurs, the calculation section 71 calculates the defect rate E for the partial frequency Nh that is equal to or greater than a predetermined threshold frequency Nmin (when the calculation requirement is met). In this case, the calculation section 71 calculates the defect rate E by dividing the number of defects Ne by the partial frequency Nh. Furthermore, the calculation section 71 does not calculate the defect rate E for partial frequencies Nh that are smaller than the threshold frequency Nmin (when the calculation requirement is not met).Alternatively, even if the calculation section 71 calculates the defect rate E for a partial frequency Nh that is smaller than the threshold frequency Nmin, the estimation section 72 determines that the defect rate E is invalid and the defect rate E is not used. The threshold frequency Nmin is set to a value large enough so that an occasional defect in a single placement operation does not unduly affect the defect rate E (so that the defect rate E has statistical reliability). Specifically, the threshold frequency Nmin is set to a value of about 20% to 30% or more of the predetermined frequency Ns, but less than 100%.

[0030] The estimation section 72 estimates, based on the defect rate E for each predetermined period, whether the tape feeder 6 or the component receiving member (roller RL, carrier tape CT) is a cause of the defect. The estimation section 72 does not perform an estimation as long as the defect rate E does not exceed a predetermined threshold value EX, and performs an estimation when the defect rate E exceeds the threshold value EX. Specifically, in a state where the first defect rate E, that is, when the first roll RL and the carrier tape CT are loaded in the tape feeder 6, exceeds the threshold value EX, the estimation section 72 performs the following estimation process.

[0031] That is, the estimation section 72 first determines whether the cause of the defect rate E exceeding the threshold value EX lies in the suction nozzle 45 or the tape feeder 6. The estimation section 72 makes a determination to apply the technique disclosed in Patent Literature 1, for example, by the applicant of the present application. Specifically, the estimation section 72 uses the combination of the suction nozzle 45 and the tape feeder 6 as a reference when the defect rate E exceeds the threshold value EX, and refers to the defect rate E only when the suction nozzle 45 or the tape feeder 6 has a change. The defect rate E to be referred to may be one already calculated or one calculated after a future change is made to the combination.

[0032] For example, in a state where the defect rate E is improved to be less than the threshold value EX when the suction nozzle 45 is changed to another suction nozzle 45 and combined with the tape feeder 6, the estimation section 72 may determine that the suction nozzle 45 is the cause. On the other hand, if the defect rate E does not improve even after replacing the suction nozzle 45, the estimation section 72 may determine that the cause lies in the tape feeder 6. When a plurality of suction nozzles 45 attached to the nozzle tool 44 pick up components from the tape feeder 6, the estimation section 72 can easily make this determination.

[0033] In a state where the defect rate E is improved when the suction nozzle 45 is combined with another tape feeder 6 to be less than the threshold value EX, the estimation section 72 can determine that the tape feeder 6 is the cause. On the other hand, if the defect rate E is not improved even after replacing the tape feeder 6, the estimation section 72 can determine that the suction nozzle 45 is the cause. When the suction nozzle 45 picks up components from multiple tape feeders 6, the estimation section 72 can easily make this determination.

[0034] If it is determined that the tape feeder 6 is the cause, no distinction is made as to whether the tape feeder 6 as a device itself is the cause or whether the roll RL or the carrier tape CT loaded in the tape feeder 6 is the cause. To distinguish this, the estimation section 72 detects a second defect rate E after the end of use of the first roll RL and the carrier tape CT and after loading the second roll RL and the carrier tape CT, if the defect rate E exceeds the threshold value EX. Then, if the second defect rate E exceeds the threshold value EX, the estimation section 72 estimates that the cause lies in the tape feeder 6. If the second defect rate E does not exceed the threshold value EX, the estimation section 72 estimates that the first roll RL or the carrier tape CT is the cause.

[0035] In other words, if the defect rate E is not improved even after replacing the roll RL and the carrier tape CT, the estimation section 72 estimates that the cause lies in the tape feeding itself. 6. If the defect rate E is improved by replacing the roll RL and the carrier tape CT, the estimation section 72 also estimates that the cause lies in the roll RL or the carrier tape CT before the replacement.

[0036] As causes of failure of the tape feeder 6 itself, factors such as increased wear and play of the sprocket 67 and the gear mechanism of the tape feed mechanism 66, a decrease in the control accuracy of the drive motor 68, deformation of the guide rail 64, and dust intrusion can be considered. Regarding these causes, it is expected that the intended function and performance can be restored by personnel performing maintenance work such as inspecting the internal condition of the tape feeder 6, replacing components, or cleaning. Therefore, it is preferable to perform maintenance of the tape feeder 6 at the appropriate time, and it is not preferable to leave the tape feeder 6 unattended.

[0037] Accordingly, the instruction section 73 provides guidance for maintenance of the tape feeder 6 using the display area when the tape feeder 6 is assumed to be the cause. If the personnel performs the maintenance according to the guidance, the function and performance of the tape feeder 6 are restored. This allows the component mounter 1 to repeat the mounting process with high operating accuracy and good production efficiency. For the tape feeders 6, there is a model according to which it is recommended that regular maintenance be performed every time a predetermined number of components are fed or every time a predetermined operating time has elapsed. If the tape feeder 6 of this model is assumed to be the cause, the instruction section 73 provides guidance for temporary maintenance.

[0038] On the other hand, factors such as a change in the shape of the part where the carrier tape CT is stored, intrusion of foreign matter, and wear of the center hole can be considered as the cause of the roll RL. In addition, factors such as an error in a thickness dimension and a width dimension of the tape, a deviation in the shape of the adhesive portion, a dimensional error or irregularity in the cavity and the feed opening, and an uneven pitch can be considered as the cause of the carrier tape CT. It is difficult to take corrective measures for this if the cause lies in the roll RL or the carrier tape CT while the roll RL or the carrier tape CT is in use, and in practice, improvement is achieved by replacing the roll RL or the carrier tape CT.

[0039] Accordingly, if it is estimated that the roll RL or the carrier tape CT is the cause, only the estimation result is displayed in the instruction section 73, or nothing is done. The roll RL and the carrier tape CT are used to the end and then replaced with another roll RL and another carrier tape CT. In many cases, the defect rate E is naturally improved after replacement.

[0040] After changing the board type K, the estimation section 72 does not use the defect rate E calculated before changing the board type. This is because it is assumed that the defect rate E is not continuous before and after the change because the placement order data 51 is changed according to the change in the board type K and the usage status of the tape feeder 6 changes. When the tape feeder 6 is detached from the pallet table 31 and the operation is interrupted and then resumed after reattaching, the estimation section 72 does not use the defect rate E calculated before the detached. This is because it is assumed that the defect rate E is not continuous before and after the reattaching because the usage status of the tape feeder 6 changes due to the reattaching.The functions of the calculation section 71, the estimation section 72 and the instruction section 73 are explained in more detail in the following description of the operations. 4. Operation of the production management device 7

[0041] Next, a specific example of the operation of the production management device 7 will be described with reference to Fig. 3 to 6. The Fig. The functional sequence shown in Figure 3 is carried out by controlling the control device 5, which contains the production management device 7. The horizontal axis of the first Fig. 4 and the horizontal axis of the second example in Fig. The values ​​of the example shown in Figure 5 indicate the total number and total frequency of assembly operations (× 10,000), respectively, and the vertical axis indicates the defect rate E (%). In addition, the bold dashed line in the vertical direction indicates the replacement time for the roll RL and the carrier tape CT, and the usage periods from the first carrier tape CT1 to the fifth carrier tape CT5 are displayed in segments.

[0042] As a premise for the first example and the second example, it has already been determined that the cause of the defect rate E exceeding the threshold value EX does not lie in the suction nozzle 45. Furthermore, it is assumed that the number of components accommodated in the first to fifth carrier tapes CT1 to CT5 before use is 24,000. In addition, the predetermined frequency Ns of the mounting process is set to 10,000, the predetermined threshold frequency Nmin is set to 50% of the predetermined frequency Ns, which is 5,000 times, and the threshold value EX of the defect rate E is set to 0.2%. Furthermore, it is assumed that the first carrier tape CT1 is installed before use in each of a plurality of tape feeders 6 under the initial condition with which the production management device 7 starts the process.The prerequisite and initial condition described above are only examples and can of course be changed.

[0043] In step S1 of Fig. 3, the control device 5 causes the suction nozzle 45 to perform the mounting operation. In the next step S2, the calculation section 71 of the production management device 7 counts the number of operations Np and the number of defects Ne for each of a plurality of tape feeders 6. For the tape feeder 6 that has supplied the components, the number of defects Ne remains unchanged when the mounting operation ends normally, while the number of operations Np increases when the mounting operation results in an error. In addition, for the tape feeder 6 that has supplied the components, the number of operations Np and the number of defects Ne do not increase.

[0044] In the next step S3, the calculation section 71 determines for each of the plurality of tape feeders 6 whether the predetermined frequency Ns for the mounting operation has been reached, that is, whether the number of operations Np reaches the predetermined frequency Ns. To avoid complexity, the following description focuses on one tape feeder 6. Until the number of operations Np reaches the predetermined frequency Ns (= 10,000), the process loop formed by steps S1 to S3 is repeated. When the number of operations Np reaches the predetermined frequency Ns, the process flow exits the start-up loop and proceeds to step S4.

[0045] In step S4, the calculation section 71 determines whether the number of operations Np with a value of 10,000 covers the replacement time of the carrier tape CT and determines the branch destination of the process flow. The process flow proceeds to step S5 when the number of operations Np with a value of 10,000 corresponds to the replacement time, and proceeds to step S6 when the number of operations Np with a value of 10,000 does not fill the replacement time. In step S5, the calculation section 71 selects the partial frequency Nh equal to or greater than the threshold frequency Nmin and causes the process flow to proceed to step S6. In step S6, the calculation section 71 calculates the defect rate E by dividing the number of defects Ne by the predetermined frequency Ns or the number of defects Ne by the partial frequency Nh (which has already been selected in step S5).After calculating the error rate E, the calculation section 71 resets the number of operations Np, the number of errors Ne and the partial frequency Nh to zero.

[0046] In the first in Fig. In the example shown in Figure 4, the number of operations Np becomes 10,000 when the total number of times reaches 10,000, and does not extend beyond the replacement time of the carrier tape CT. Therefore, in the calculation section 71, the defect rate E1 is calculated by dividing the number of defects Ne generated in the first to the 10,000th mounting operations by the predetermined number of times Ns (= 10,000). When the total number of times reaches 20,000, the calculation section 71 further calculates the defect rate E2 by dividing the number of defects Ne generated in the 10,001st to the 20,000th mounting operations by the predetermined number of times Ns.

[0047] When the total frequency reaches 30,000, the number of operations Np becomes 10,000 and spans the replacement time from the first carrier belt CT1 to the second carrier belt CT2. The first partial frequency Nh for the use of the first carrier belt CT1 before replacement is 4,000 (= 24,000 - 20,000), and the second partial frequency Nh for the use of the second carrier belt CT2 after replacement is 6,000 (= 30,000 - 24,000). The first partial frequency Nh (= 4,000) is less than the threshold frequency Nmin (= 5,000), thus not meeting the calculation requirement, while the second partial frequency Nh (= 6,000) is equal to or greater than the threshold number Nmin, thus meeting the calculation requirement. Therefore, the calculation section 71 calculates the error rate E3 by dividing the number of errors Ne by the second partial frequency Nh (= 6,000) for the 24,001st to 30,000th.Assembly process using the second carrier tape CT2.

[0048] The calculation section 71 calculates the defect rate E4 up to the defect rate E10 using the same calculation method. The defect rate E4, the defect rate E6, the defect rate E7, and the defect rate E9 are calculated for a predetermined period of time, excluding the replacement time of the carrier tape CT. The defect rate E5 is calculated by dividing the number of defects Ne by the partial frequency Nh (= 8,000) for the 40,001st to 48,000th placement process using the second carrier tape CT2. The defect rate E8 is calculated by dividing the number of defects Ne by the partial frequency Nh (= 8,000) for the 72,001st to 80,000th placement process using the fourth carrier tape CT4. The error rate E10 is calculated by dividing the number of errors Ne by the partial frequency Nh (= 6,000) for the 90,001st to 96,000th placement operation using the fourth carrier tape CT4. In the second example, shown in Fig. 5, the calculation section 71 calculates the error rate E11 to the error rate E20 according to the same calculation method as in the first example.

[0049] In the next step S7, the estimation section 72 compares the error rate E calculated by the calculation section 71 with the threshold EX to determine the branch destination of the process flow. If the error rate E does not exceed the threshold EX, the estimation section 72 returns to step S1 in the process flow and does not perform the estimation operation. If the error rate E exceeds the threshold EX, the estimation section 72 causes the process flow to proceed to step S8 and perform the estimation operation.

[0050] The content of the estimation operation of the estimation section 72 in step S8 is shown in the table in Fig. 6. The pre-replacement failure rate EF in the table indicates the failure rate E before replacing the carrier tape CT, and the post-replacement failure rate ER indicates the failure rate E after replacing the carrier tape CT. The symbol L indicates that the failure rate E does not exceed the threshold EX, and the symbol H indicates that the failure rate E exceeds the threshold EX. When multiple failure rates E are calculated for a carrier tape CT and one of the failure rates E exceeds the threshold EX, the failure rate E is indicated by the symbol H.

[0051] As in case 1) of Fig. 6, in the estimation section 72, the cause is not estimated if both the failure rate EF before replacement and the failure rate ER after replacement do not exceed the threshold EX. As shown in Case 2), in the estimation section 72, the cause is not estimated if the failure rate EF before replacement does not exceed the threshold EX and the failure rate ER after replacement increases and exceeds the threshold EX. In this case, the estimation section 72 performs the estimation of the cause after transitioning to Case 3) or Case 4), which involves the next replacement of the carrier tape CT and the calculation of the failure rate E after replacement.

[0052] If, as shown in Case 3), the defect rate EF before replacement exceeds the threshold EX and the defect rate ER after replacement decreases and does not exceed the threshold EX, the estimation section 72 estimates that the cause lies in the roll RL or the carrier tape CT before replacement. If, as shown in Case 4), both the defect rate before replacement EF and the defect rate after replacement ER exceed the threshold EX, the estimation section 72 estimates that the cause lies in the tape feeder 6.

[0053] In the first example, the error rates E1 to E6 calculated in sequence do not exceed the threshold EX. Therefore, the process flow is Fig. 3 in the calculation of the failure rate E1 to E6 from step S7 to step S1. The next calculated failure rate E7 is approximately 0.23% and exceeds the threshold EX (= 0.2%), and the process flow continues with step S8. At this point, the estimation section 72 does not perform a cause estimation based on the failure rate EF before replacement (failure rate E3, failure rate E4, failure rate E5) and the failure rate ER after replacement (failure rate E7) corresponding to case 2) in Fig. 6 through.

[0054] Furthermore, the next calculated defect rate E8 is approximately 0.25% and exceeds the threshold EX. The replacement of the carrier tape CT occurs between the defect rate E7 when using the third carrier tape CT3 and the defect rate E8 when using the fourth carrier tape CT4. Therefore, in the estimation section 72, it is estimated that tape feeder 6 is the cause based on the defect rate EF before the replacement (defect rate E7) and the defect rate ER after the replacement (defect rate E8), which corresponds to Case 4.

[0055] On the other hand, in the second example, the failure rate E11 to the failure rate E16, calculated in the specified order, show a similar transition as in the first example and do not exceed the threshold EX. The next calculated failure rate E17 is approximately 0.29% and exceeds the threshold EX (= 0.2%). At this time, the estimation section 72 does not perform a root cause estimation based on the failure rate EF before replacement (failure rate E13, failure rate E14, failure rate E15) and the failure rate ER after replacement (failure rate E17), which corresponds to Case 2.

[0056] Furthermore, the next calculated failure rate E18 is approximately zero and does not exceed the threshold EX. The replacement of the carrier tape CT occurs between the failure rate E17 when using the third carrier tape CT3 and the failure rate E18 when using the fourth carrier tape CT4. Therefore, in the estimation section 72, it is estimated that the cause is the reel RL or the third carrier tape CT3 before the replacement, based on the failure rate EF (failure rate E17) before the replacement and the failure rate ER (failure rate E18) after the replacement, which corresponds to Case 3).

[0057] In the next step S9, the instruction section 73 determines whether the cause is assumed to be in the tape feeder 6 and determines the branch destination of the process flow. The process flow proceeds to step S10 if an estimation is made, and returns to step S1 if no estimation is made. In step S10, the instruction section 73 provides guidance for maintenance of the tape feeder 6. In the next step S11, the operator removes the tape feeder 6 according to the guidance and mounts another tape feeder 6. After that, the process flow returns to step S1, and the mounting operation continues. The operator performs maintenance on the removed tape feeder 6 and prepares it for the next use.

[0058] In the first example, after calculating the defect rate E8, since it is assumed that the cause lies in the tape feeder 6, the instruction section 73 is activated. The operator replaces the tape feeder 6 with another tape feeder 6 according to the instruction after the use of the fourth carrier tape CT4 is completed. Another tape feeder 6 supplies components using the inserted fifth carrier tape CT5. Therefore, even if the defect rate E9 and the defect rate E10 when using the fourth carrier tape CT4 exceed the threshold EX, the defect rate EA is improved to less than the threshold EX when using the fifth carrier tape CT5. The operator can also perform the replacement of the tape feeder 6 while using the fourth carrier tape CT4. In any case, the worker can perform maintenance on the tape feeder 6 at the appropriate time based on the guidance in the instruction section 73.

[0059] On the other hand, in the second example, instruction section 73 does not operate because it is assumed that the roll RL or the third carrier tape CT3 before replacement is the cause. No special action is required from the personnel. Nevertheless, the defect rate E18, the defect rate E19, and the defect rate E20 are kept below the threshold EX after replacement with the fourth carrier tape CT4. Since instruction section 73 does not provide guidance regarding unnecessary maintenance of the tape feeder 6, the burden on the personnel is not unnecessarily increased.

[0060] Since the calculation section 71 in the production management device 7 of the first embodiment calculates the defect rate E for each predetermined period (predetermined frequency Ns) divided before and after the replacement time of the component receiving member (reel RL and carrier tape CT), the estimation section 72 can estimate whether the tape feeder 6 or the component receiving member is the cause of the defect based on how the defect rate E (defect rate before replacement EF, defect rate after replacement ER) differs before and after the replacement time. 5. Structure of the production management device 7A of the second embodiment

[0061] Next, a structure of the manufacturing management apparatus 7A of the second embodiment will be described with reference to Fig. 7 mainly with respect to points that differ from the first embodiment. As in Fig. As shown in FIG. 7, in the production management device 7A of the second embodiment, the judgment section 74 and the temporary stop control section 75 are added, and the function of the calculation section 71A is changed. In the second embodiment, the hardware configuration of the component mounter 1 is the same as the hardware configuration in the first embodiment.

[0062] In the first embodiment, the predetermined number of times Ns of mounting operations corresponding to the predetermined period of time is set regardless of the number of components housed in a carrier tape CT before use. For this reason, a partial frequency Nh occurs unevenly, so that a denominator for calculating the defect rate E fluctuates and the calculation process becomes complicated. The calculation section 71A of the second embodiment sets the denominator for calculating the defect rate E to a fixed number, so that the calculation process is simplified. Specifically, the calculation section 71A sets the predetermined number Ns of mounting operations corresponding to the predetermined period of time based on the number of components housed in the carrier tape CT before use.For example, the calculation section 71A sets the number of components housed in the carrier tape CT before use as the predetermined frequency Ns. Alternatively, the calculation section 71A equally divides the number of components housed in the carrier tape CT before use to set it as the predetermined frequency Ns.

[0063] The judgment section 74 is executed after the estimation section 72 determines the part constituting the cause by estimation. The judgment section 74 refers to the estimation result of the estimation section 72 to judge which of the three parts, namely the component feed unit (tape feeder 6), the component receiving member (reel RL and carrier tape CT), and the data (mounting order data 51), is / are the cause. Similar to the estimation section 72, in the judgment section 74, a judgment is performed to apply the technique disclosed in Patent Literature 1 by the applicant of the present application. Specifically, the judgment section 74 selects a part determined by estimation section 72 by estimation as the first factor, selects a part of the mounting order data 51 as the second factor, and applies the technique disclosed in Patent Literature 1.

[0064] As a second factor, for example, shape data for each component type can be selected in the mounting order data 51. If the shape data with a larger error than the actual shape of the component is the cause, the judging section 74 can judge that the mounting order data 51 is the cause. Since the technique disclosed in Patent Literature 1 is limited in application, there may be cases where the judging section 74 is unable to specify and judge a part. In this case, the judging section 74 may specify multiple parts that could be possible causes according to the judgment result. In fact, the multiple parts may contribute to an increase in the defect rate E.As can be seen from the above description, the parts for which no cause is obtained by estimation according to Estimation Section 72 are not assessment targets of Assessment Section 74 and are not assessed as parts that are candidates for cause.

[0065] The temporary stop control section 75 compares the defect rate E with the second threshold EY each time the defect rate E is calculated. If the defect rate E exceeds the second threshold EY, the temporary stop control section 75 temporarily stops the mounting process. The second threshold EY is set to be greater than the threshold EX to ensure that the economic loss from disposing of the component due to the defect and the time loss from retrying the mounting process to correct the defect do not become excessive.

[0066] 6. Operation of the Production Management Device 7A of the Second Embodiment Next, an operation of the production management device 7A of the second embodiment will be described with reference to Fig. 8 and Fig. 9. The Fig. 8 is carried out according to a control by the control device 5, which contains the production management device 7A. The process shown in Fig. The third example shown in Figure 9 is displayed using the same format as the first example and the second example.

[0067] In step S21 of Fig. 8, the calculation section 71A of the production management device 7A sets the predetermined frequency Ns of the mounting operation according to the predetermined period of time. In the third example shown in Fig.As shown in Figure 9, the calculation section 71A divides the number of components (= 24,000) accommodated in a carrier tape CT before use into two equal parts and sets the predetermined frequency Ns (= 12,000). The configuration is not limited to this; the predetermined frequency Ns may be 24,000, which is equal to the number of components, or may be 8,000, which is achieved by dividing the number of components into three equal parts.

[0068] The following steps S22 to S25 correspond to steps S1 to S3 and step S6 of the first embodiment, and the calculation section 71A calculates the defect rate E. However, the process corresponding to steps S4 and S5 of the first embodiment is not required, and the process flow is simplified. When the number of defects is small, on the order of a few defects, among the number of components accommodated in the carrier tape CT, the calculation section 71A inserts the number of defects into the predetermined frequency Ns and calculates the defect rate E.

[0069] In the third example, the error rate E21 is calculated when the first carrier band CT1 is half used, and the error rate E22 is calculated when the first carrier band CT1 is fully used. Similarly, the error rate E23 and the error rate E24 are calculated when the second carrier band CT2 is used, the error rate E25 and the error rate E26 are calculated when the third carrier band CT3 is used, and the error rate E27 and the error rate E28 are calculated when the fourth carrier band CT4 is used. The error rate E21 to the error rate E25 does not exceed the threshold EX, and the error rate E26 to the error rate E28 does exceed the threshold EX.

[0070] In the next step S26, the temporary stop control section 75 compares the error rate E21 to the error rate E28 with the second threshold value EY each time the error rate E21 to the error rate E28 is calculated, and determines the branch destination of the process flow. Since the error rate E21 to the error rate E28 does not exceed the second threshold value EY, the process flow proceeds to step S28. In step S28, after the error rate E27 is calculated, the estimation section 72 estimates that the tape feeder 6 is the cause based on the error rate EF before replacement (error rate E26) and the error rate ER after replacement (error rate E27), which corresponds to case 4.

[0071] In the next step S29, processing is carried out by the judging section 74. The judgment result of the judging section 74 is one of the following (A) to (C). (A) Tape feeder 6 is a cause. (B) Assembly order data 51 is a cause. (C) Tape feeder 6 or assembly order data 51 is / are a cause.

[0072] In the next step S30, the judgment section 74 displays the judgment result using the display section. If the judgment result is (A) or (C), the instruction section 73 operates in parallel and provides guidance for the maintenance of the tape feeder 6. After that, the process flow returns to step S22.

[0073] In the third example, the error rate E29 is calculated when using the fifth carrier tape CT5 by repeating steps S22 to S25. In step S26, the temporary stop control section 75 causes the process flow to proceed to step S27 based on the error rate E29 exceeding the second threshold EY. In step S27, the temporary stop control section 75 temporarily stops the mounting process. Furthermore, the temporary stop control section 75 notifies the personnel via the display area or another communication method that the mounting process has been temporarily stopped.

[0074] In the production management device 7A of the second embodiment, the predetermined frequency Ns is set based on the number of components accommodated in a carrier tape CT before use, so that the denominator for calculating the defect rate E becomes a fixed number and the calculation process of the calculation section 71A is simplified. In addition, due to the function of the judgment section 74, a judgment is made regarding the possibility that the mounting order data 51 is the cause. Moreover, due to the function of the temporary stop control section 75, since the mounting operation is temporarily stopped when the defect rate E exceeds the second threshold value EY, the economic loss due to the disposal of the components due to the defect and the time loss due to retrying the mounting operation do not become excessively large. 7. Applications and modifications of embodiments

[0075] The calculation section 71 of the first embodiment may be replaced with the calculation section 71A of the second embodiment. In the second embodiment, only the judgment section 74 or the temporary stop control section 75 may be added as needed without changing the calculation section 71. Furthermore, in the second embodiment, the temporary stop control section 75 can calculate the error rate E using a denominator smaller than the predetermined frequency Ns and determine whether a temporary stop is necessary. This advances the timing of the temporary stop, thereby reducing economic loss and time loss. Furthermore, the first and second embodiments are suitable for various applications and modifications. List of reference symbols

[0076] 1: Component mounter, 2: PCB conveyor, 3: Component feeder, 4: Component transfer device, 45: Suction nozzle, 5: Control device, 51: Mounting order data, 6: Tape feeder, 7, 7A: Production management device, 71, 71A: Calculation section, 72: Estimation section, 73: Instruction section, 74: Judgment section, 75: Temporary stop control section, K: PCB, CT: Carrier tape, CT1 to CT5: First to fifth carrier tapes, RL: Reel, E, E1 to E10, EA, E11 to E20, E21 to E29: Defect rate, EF: Defect rate before replacement, ER: Defect rate after replacement, EX: Threshold, EY: Second threshold QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] WO 2020 / 188774

[0004]

Claims

[1] A manufacturing management device comprising: a calculation section configured to calculate an error rate of a mounting operation for mounting a component supplied from a component supply unit on a circuit board, wherein a component receiving element is replaceably inserted in a component mounter for each predetermined period divided according to a time including at least one replacement time of the component receiving element after repeated execution of the mounting operation; and an estimation section configured to determine, by estimation, whether the component feeding unit and / or the component receiving member are a cause of failure based on the failure rate for each predetermined period. [2] The manufacturing management apparatus according to claim 1, wherein the estimation section does not perform estimation when the error rate does not exceed a predetermined threshold, and performs estimation when the error rate exceeds the threshold. [3] The manufacturing management apparatus according to claim 2, wherein, in a state where a first failure rate of the mounting operation exceeds the threshold when a first component receiving member is mounted in the component supply unit, the estimation section estimates that the component supply unit is the cause when a second failure rate of the mounting operation after mounting a second component receiving member in place of the first component receiving member exceeds the threshold, and estimates that the component receiving member is the cause when the second failure rate does not exceed the threshold. [4] The manufacturing management apparatus according to any one of claims 1 to 3, wherein the predetermined period of time is set based on a predetermined frequency of the mounting operation. [5] The manufacturing management device according to claim 4, wherein, when the predetermined frequency of the mounting operation is divided according to the replacement time of the component receiving member so that a partial frequency occurs, the calculation section calculates the failure rate for the partial frequency equal to or greater than a predetermined threshold frequency and does not calculate the failure rate for the partial frequency less than the threshold frequency. [6] The manufacturing management device according to any one of claims 1 to 3, further comprising: an instruction section configured to provide guidance for maintenance of the component feeding unit when the component feeding unit is judged to be the cause. [7] The manufacturing management apparatus according to any one of claims 1 to 3, wherein the estimation section after a change of the board type does not use the defect rate calculated before the change of the board type. [8] The production management device according to any one of claims 1 to 3, wherein the component mounter includes data used for the mounting process, and the production management device includes a judging section configured to judge whether the component supply unit and / or the component receiving member and / or the data is the cause with respect to an estimation result of the estimation section. [9] The manufacturing management device according to claim 2 or 3, further comprising: a temporary stop control section configured to temporarily stop the mounting operation when the error rate exceeds a predetermined second threshold value that is greater than the threshold value. [10] The production management apparatus according to any one of claims 1 to 3, wherein the component receiving member is a carrier tape holding a plurality of components and a reel on which the carrier tape is wound, and the component feeding unit is a tape feeder into which the carrier tape is replaceably inserted.

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