Production plan creation method and production plan creation device

Abstract

To provide a production plan creation method and a production plan creation device capable of automatically creating a production plan with high prediction accuracy and production efficiency.SOLUTION: A production plan creation method for creating a production plan for producing a plurality of types of mounting boards by a plurality of production lines, includes the steps of: calculating, for each production line, an approximate cycle time required to produce each of the plurality of types of mounting boards in the production line; assigning each of the plurality of types of mounting boards to any of the plurality of production lines based on the calculated approximate cycle time; calculating the cycle time required for producing the mounting board of an assigned type in the production line; creating the production plan based on the calculated cycle time; calculating an evaluation index value for the created production plan; and changing assignment of the type relative to the production line based on the calculated evaluation index value.SELECTED DRAWING: Figure 10

Description

[Technical field]

[0001] The present invention relates to a production planning method and a production planning device for creating a production plan for producing a plurality of types of products using a plurality of production lines. [Background technology]

[0002] When producing products such as mounted boards with components mounted on a board using multiple production lines equipped with production equipment, a production plan is created that includes the allocation of product types to each production line and the production sequence so that a specified production volume of multiple product types can be produced by a specified production delivery date. In addition, production data is created for each production line, including the configuration of production equipment and the production work sequence according to the product types to be produced. When creating the production data, the configuration of the production equipment is created so that the number of setup changes required to change the configuration of the production equipment when changing the product type is reduced.

[0003] Meanwhile, in a production line, production data cannot be created until a production plan is created and the product type to be produced is decided, but conversely, if the production data is not decided, the accurate time required to produce the product type cannot be calculated, and a highly accurate production plan cannot be created. In other words, the production plan and production data are in a circular reference relationship, and in order to simultaneously create a production plan and production data with high prediction accuracy and production efficiency, a highly skilled and experienced creator must spend a long time creating them. Patent Document 1 describes a system that supports the creation work of workers when simultaneously creating a production plan and production data (processing process plan). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2013 / 137159 Summary of the Invention [Problem to be solved by the invention]

[0005] However, with conventional technologies including the system described in Patent Document 1, the quality of the production plans and production data created depended on the skills of the workers, and there was a problem in that the time required for the creation work increased exponentially as the number of varieties to be produced increased.

[0006] Therefore, an object of the present invention is to provide a production plan creation method and a production plan creation device that can automatically create a production plan with high prediction accuracy and production efficiency. [Means for solving the problem]

[0007] A production plan creation method of the present invention is a production plan creation method for creating a production plan for producing a plurality of types of mounted boards using a plurality of production lines, the production plan creation method comprising the steps of: calculating, for each production line, an estimated cycle time required to produce each of the plurality of types of mounted boards on the production line; assigning each of the plurality of types of mounted boards to one of the plurality of production lines based on the calculated estimated cycle time; calculating a cycle time required to produce the assigned type of mounted board on the production line; creating a production plan based on the calculated cycle time; calculating an evaluation index value for the created production plan; and changing the allocation of the types to the production lines based on the calculated evaluation index value.

[0008] The production plan creation device of the present invention is a production plan creation device that creates a production plan for producing multiple varieties of mounted boards using multiple production lines, and includes an estimated cycle time calculation unit that calculates, for each production line, an estimated cycle time required to produce each of the multiple varieties of mounted boards on the production line, a production line allocation unit that allocates each of the multiple varieties of mounted boards to one of the multiple production lines based on the calculated estimated cycle time, a cycle time calculation unit that calculates the cycle time required to produce the allocated variety of mounted boards on the production line, a production plan updating unit that creates a production plan based on the calculated cycle time, an evaluation index value calculation unit that calculates an evaluation index value for the created production plan, and an allocation change unit that changes the allocation of the varieties to the production lines based on the calculated evaluation index value. Effect of the Invention

[0009] According to the present invention, a production plan with high prediction accuracy and production efficiency can be automatically created. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a configuration explanatory diagram of a component mounting system according to an embodiment of the present invention; [Diagram 2] FIG. 1 is a configuration explanatory diagram of a component mounting line provided in a component mounting system according to an embodiment of the present invention; [Diagram 3] FIG. 1 is a plan view of a component mounting device provided in a component mounting system according to an embodiment of the present invention; [Figure 4] FIG. 1 is a partial cross-sectional view of a component mounting device provided in a component mounting system according to an embodiment of the present invention. [Diagram 5] FIG. 1 is a block diagram showing the configuration of a management computer (production plan creation device) according to an embodiment of the present invention. [Figure 6] FIG. 2 is an explanatory diagram of an example of production plan information used in a management computer (production plan creation device) according to an embodiment of the present invention; [Figure 7]FIG. 2 is an explanatory diagram of an example of cycle time information calculated in a management computer (production plan creation device) according to an embodiment of the present invention; [Figure 8] 1A, 1B, and 1C are explanatory diagrams of an example of a product commonality calculated in a management computer (production plan creation device) according to an embodiment of the present invention. [Figure 9] 1A and 1B are explanatory diagrams of an example of a production plan created in a management computer (a production plan creation device) according to an embodiment of the present invention. [Figure 10] FIG. 1 is a flow diagram of a production plan creation method according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] An embodiment of the present invention will be described in detail below with reference to the drawings. The configurations, shapes, etc. described below are examples for the purpose of explanation, and can be appropriately changed according to the specifications of the component mounting system, component mounting line, component mounting device, etc.

[0012] In the following, corresponding elements in all drawings are given the same reference numerals, and duplicated explanations are omitted. In Fig. 3 and in some parts described later, the X direction (left-right direction in Fig. 3) in the board transport direction and the Y direction (up-down direction in Fig. 3) perpendicular to the board transport direction are shown as two axial directions perpendicular to each other in a horizontal plane. In Fig. 4, the Z direction (up-down direction in Fig. 4) is shown as a height direction perpendicular to the horizontal plane. The Z direction is the up-down direction or perpendicular direction when the component mounting device is installed on a horizontal plane.

[0013] First, the configuration of component mounting system 1 will be described with reference to Fig. 1. Component mounting system 1 is configured such that three component mounting lines L1 to L3 arranged on floor F are connected by a communication network 2 and managed by a management computer 3. The component mounting lines L1 to L3 are arranged in a production area Ap provided on floor F. As described later, each component mounting line L1 to L3 is configured by connecting multiple production facilities including a screen printing device and a component mounting device, and has the function of producing mounted boards (products) with components mounted on a board. Note that the number of component mounting lines L1 to L3 provided in component mounting system 1 does not need to be three, and may be two or four or more.

[0014] A placement work support device 4 is disposed in a preparation area As which is different from the production area Ap provided on floor F. The placement work support device 4 is connected to a management computer 3 via a communication network 2. A replacement cart 5 which is the subject of placement work, which will be described later, is connected to the placement work support device 4. A plurality of carts 5 in various states, such as before, during, or after placement work, are stored in the preparation area As. Additionally, the preparation area As stores removable elements such as a plurality of screen masks, tape feeders 9, mounting heads 12, suction nozzles 12b, and reels 17 (see FIG. 4) which are shared by the production equipment disposed on floor F.

[0015] In Fig. 1, a placement operation is performed on a cart 5 connected to a placement operation support device 4 according to a work instruction corresponding to the type of mounted board to be produced in the component mounting lines L1 to L3. As the placement operation, a worker performs an operation of removing a plurality of tape feeders 9 and reels 17 that supply the specified components from the cart 5, and an operation of attaching them to the specified positions on the cart 5. For the carts 5 in the preparation area As including the carts 5 connected to the placement operation support device 4, placement operation can be performed in parallel with the production of mounted boards in the component mounting lines L1 to L3. Hereinafter, the preparation operation for a type change outside the component mounting lines L1 to L3, including the placement operation on the carts 5, is referred to as an off-site setup operation.

[0016] When changing the type of mounted boards produced in the component mounting lines L1 to L3, the worker moves the cart 5 that has completed placement work in the preparation area As to the component mounting line L1 to L3 and performs a type switching operation to replace it with the cart 5 attached to the component mounting device. In the type switching operation, the worker moves replacement screen masks, tape feeders 9, mounting heads 12, suction nozzles 12b, reels 17, etc. stored in the preparation area As to the component mounting line L1 to L3 and replaces them. Hereinafter, the preparation operation for changing the type in the component mounting lines L1 to L3, including the type switching operation to replace the cart 5, is referred to as internal setup operation.

[0017] Next, the detailed configuration of component mounting lines L1 to L3 will be described with reference to Fig. 2. The component mounting lines L1 to L3 have the same configuration, and below, component mounting line L1 will be described. The component mounting line L1 is configured by connecting production equipment such as board supply device M1, screen printing device M2, component mounting devices M3 to M6, reflow device M7, and board recovery device M8 in series from the upstream side (left side of the paper) to the downstream side (right side of the paper) in the board transport direction. Note that the component mounting line L1 is a group of production equipment connected via a communication network 2, and the production equipment does not have to be physically connected to each other.

[0018] The board supplying device M1, the screen printing device M2, the component mounting devices M3 to M6, the reflow device M7, and the board collecting device M8 are connected to a management computer 3 via a communication network 2. The board supplying device M1 has a storage unit such as a rack for storing a plurality of boards, and performs a board supplying operation of supplying the board taken out of the storage unit to a downstream device. The screen printing device M2 performs a solder printing operation of printing solder on the board carried in from the upstream side through a screen mask attached to the printing operation unit. The component mounting line L1 may be provided with a solder application device that applies solder to the board using a dispenser in parallel with the screen printing device M2 or in place of the screen printing device M2. The screen printing device M2 and the solder application device are printing devices that deposit solder on the board.

[0019] The component mounting devices M3 to M6 perform a component mounting operation in which components are mounted on a board on which solder has been deposited using a mounting head 12. The component mounting line L1 is not limited to a configuration in which the component mounting devices M3 to M6 are four, and may have one to three or five or more component mounting devices M3 to M6. The reflow device M7 performs a board heating operation in which the board carried into the device is heated by a board heating unit to harden the solder on the board and bond the electrode part of the board to the component. The board recovery device M8 has a storage unit such as a rack for storing multiple boards, and performs a board recovery operation in which the board carried out by an upstream device is received and recovered in the storage unit.

[0020] Next, the configuration of component mounting devices M3 to M6 will be described with reference to Figs. 3 and 4. The component mounting devices M3 to M6 have the same configuration, and here, component mounting device M3 will be described. The component mounting device M3 has a function of mounting a component D on a board B. In Fig. 3, a board transport mechanism 7 is installed in the X direction at the center of the base 6. The board transport mechanism 7 transports the board B carried in from the upstream side in the X direction, and positions and holds it at a mounting operation position by a mounting head 12, which will be described below. In addition, the board transport mechanism 7 carries out the board B, on which the component mounting operation has been completed, to the downstream side. Component supply units 8 are installed on both sides of the board transport mechanism 7.

[0021] The component supply unit 8 is fitted with carts 5 on which a plurality of tape feeders 9 are mounted in parallel in the X direction. The tape feeders 9 feed the carrier tape, on which pockets for storing the components D are formed, in a direction (tape feed direction) from the outside of the component supply unit 8 toward the board transport mechanism 7 to supply the components D to the component removal position where the mounting head 12 picks up the components D. In other words, the tape feeder 9 is a component supply device that supplies the components D. Note that, in addition to the tape feeder 9, the component supply device may be a tray feeder that supplies the components D placed on a tray, a stick feeder that supplies the components D aligned and held on a hollow stick, or the like.

[0022] In Fig. 3, a Y-axis table 10 equipped with a linear drive mechanism is disposed on both ends in the X direction on the upper surface of base 6. A beam 11 similarly equipped with a linear mechanism is coupled to Y-axis table 10 so as to be freely movable in the Y direction. A mounting head 12 is attached to beam 11 so as to be freely movable in the X direction. Mounting head 12 is equipped with multiple (eight in this example) nozzle units 12a. Multiple types of mounting heads 12, differing in the number of nozzle units 12a, are prepared.

[0023] 4, a suction nozzle 12b that vacuum-sucks and holds a component D is attached to the lower end of each nozzle unit 12a. A number of types of suction nozzles 12b with different nozzle shapes are prepared in accordance with the size, shape, and other factors of the component D to be sucked.

[0024] In FIG. 3, the Y-axis table 10 and the beam 11 constitute a mounting head moving mechanism 13 that moves the mounting head 12 in the horizontal direction (X direction, Y direction). The mounting head moving mechanism 13 and the mounting head 12 pick up the component D by suction with the suction nozzle 12b from the component take-out position of the tape feeder 9 attached to the component supply unit 8. Then, the mounting head moving mechanism 13 performs a component mounting operation by transferring the mounting head 12 to the mounting position of the board B held by the board transport mechanism 7 and mounting the component. The time it takes for the mounting head 12 to take out the component D from the tape feeder 9 and mount it on the board B depends on the position of the tape feeder 9 on the cart 5 (the configuration of the production equipment). For example, by arranging the tape feeder 9 that supplies the component D, which is mounted on the board B in a large number of mounting points, near the center of the cart 5, the moving distance of the mounting head 12 can be reduced and the mounting time can be shortened.

[0025] 3 and 4, a head camera 14 is attached to the beam 11, which is located on the underside of the beam 11 and moves integrally with the mounting head 12. As the mounting head 12 moves, the head camera 14 moves above the board B positioned at the mounting operation position of the board transport mechanism 7, and captures an image of a board mark (not shown) provided on the board B to recognize the position of the board B.

[0026] A component recognition camera 15 is installed between the component supply unit 8 and the board transport mechanism 7. When the mounting head 12 moves upward after picking up the component D from the component supply unit 8, the component recognition camera 15 captures an image of the component D held by the suction nozzle 12b to recognize the holding position, etc. When the mounting head 12 mounts the component D on the board B, the mounting position is corrected taking into account the recognition result of the board B by the head camera 14 and the recognition result of the component D by the component recognition camera 15.

[0027] 4, a reel 17 around which a carrier tape 16 storing components D is wound is held on the front side of the dolly 5. The tape feeder 9 transports the carrier tape 16 stored on the reel 17 in the tape feed direction to supply the components D to a component pick-up position by the mounting head 12. A number of types of tape feeders 9 are prepared, each with different widths corresponding to the width of the carrier tape 16 to be transported.

[0028] Next, the configuration of the management computer 3 will be described with reference to Fig. 5. The management computer 3 includes a processing unit 20, a production plan storage unit 23 which is a storage device, a production data storage unit 24, and a line information storage unit 25, as well as an input unit 26 and a display unit 27. The processing unit 20 is a data processing device such as a CPU, and includes a production plan creation unit 21 and a production data creation unit 22 as internal processing units. The management computer 3 does not need to be configured as a single computer, and may be configured as a plurality of devices. For example, all or part of the storage device may be provided in a cloud via a server.

[0029] The input unit 26 is an input device such as a keyboard, a touch panel, a mouse, etc., and is used when inputting operation commands, data, etc. The display unit 27 is a display device such as a liquid crystal panel, and in addition to displaying various data stored in each memory unit, it also displays various information such as an operation screen for operation by the input unit 26, a production plan display screen, and a notification screen.

[0030] 5, production plan storage unit 23 stores production plan information 23a, product type information 23b, cycle time information 23c, switching time information 23d, evaluation index value information 23e, etc. Production plan information 23a stores a production plan including, for each lot number that identifies the lot of the mounted boards to be produced, information that identifies the product type to be produced, the number of sheets to be produced, the possible start date and time when production can be started and the production delivery date, information that identifies component mounting lines L1 to L3 that produce the mounted boards, the scheduled start date and time and the scheduled end date and time, and the work schedule of workers.

[0031] An example of the production plan information 23a will now be described with reference to FIG. 6. The production plan information 23a includes a lot number 31, a product type number 32, a production quantity 33, a start date and time 34, and a production delivery date 35. The lot number 31 is information for identifying the lot of mounted boards produced in the component mounting lines L1 to L3. The product type number 32 is information for identifying the product type of the mounted board. The production quantity 33 is the number of mounted boards produced in the lot. The start date and time 34 is the date and time when the components D and the like are available on the floor F and production can be started. The production delivery date 35 is the date and time when the production of the mounted boards must be completed. Hereinafter, a lot with a lot number 31 of "A" will be simply referred to as "lot A", and a product type with a product type number 32 of "X1" will be simply referred to as "product type X1", etc.

[0032] 5, product type information 23b stores information required for component mounting work, such as the component type and mounting position of component D to be mounted on board B, for each product type number 32 that specifies the product type of mounted board to be produced. Cycle time information 23c stores, for each product type of mounted board, the maximum value of the cycle time for each production facility from when board B is carried into the production facility equipped in component mounting lines L1 to L3 until it is carried out after production work is performed.

[0033] Switching time information 23d stores the external setup work time and internal setup work time for switching the type of product being produced for each combination of types before and after the switch. Evaluation index value information 23e stores evaluation index values ​​for each type of mounting board, such as an index relating to production efficiency, such as the number of components (number of mounting points) mounted on board B per hour, and an index relating to human resources, such as the number of workers (man-hours) required for production. Note that the more the number of mounting points per hour and the fewer the number of workers, the higher the evaluation.

[0034] 5, production data storage unit 24 stores production data information 24a and the like. Production data information 24a stores information about the configuration of production equipment, such as the arrangement positions of tape feeders 9 and reels 17 on dolly 5, and the positions and types of mounting heads 12 and suction nozzles 12b attached to component mounting devices M3 to M6, for each type (lot) assigned to component mounting lines L1 to L3. Furthermore, production data information 24a also includes, in the case where types (lots) assigned to component mounting lines L1 to L3 are grouped, information about types (lots) belonging to the same group, and information about the arrangement positions of tape feeders 9 and reels 17 commonly arranged on dolly 5.

[0035] The line information storage unit 25 stores line configuration information 25a, production equipment information 25b, and the like. The line configuration information 25a stores information on the configuration of the production line, such as the type of production equipment constituting each of the component mounting lines L1 to L3 and the order in which they are connected. The production equipment information 25b stores information on the time required for production, such as the time required for each task in the production work, for each type of production equipment constituting the component mounting lines L1 to L3. For example, the production equipment information 25b stores the time required to carry in and out the board B in each production equipment, the printing time per board in the screen printing device M2, the mounting time per component in the component mounting devices M3 to M6, and the like.

[0036] 5, the production plan creation unit 21 includes, as its internal processing units, an estimated cycle time calculation unit 21a, a production line allocation unit 21b, a production sequence creation unit 21c, a cycle time calculation unit 21d, a production plan update unit 21e, a switching time calculation unit 21f, an evaluation index value calculation unit 21g, an allocation change unit 21h, and a delay determination unit 21i. The production data creation unit 22 includes, as its internal processing units, a group creation unit 22a, and an equipment configuration determination unit 22b.

[0037] The approximate cycle time calculation unit 21a calculates an approximate cycle time required to produce a variety under conditions that optimize the configuration of the production equipment for each production line and each variety, based on information (production plan information 23a) on the variety (lot) to be produced, including the production volume (number of sheets produced 33) and production delivery date 35, and information (line configuration information 25a, production equipment information 25b) on the production equipment of multiple production lines (component mounting lines L1 to L3), and stores the calculated approximate cycle time in cycle time information 23c.

[0038] Here, with reference to Fig. 7, an example of cycle time information 23c including an estimated cycle time calculated based on production plan information 23a shown in Fig. 6 will be described. The cycle time information 23c stores, for each product type number 32, an estimated cycle time 36a when produced on component mounting line L1, an estimated cycle time 36b when produced on component mounting line L2, and an estimated cycle time 36c when produced on component mounting line L3.

[0039] The estimated cycle time 36 differs for each of the component mounting lines L1-L3 due to factors such as the configuration of the production equipment on those lines. For example, for product type X1, the estimated cycle time 36a on component mounting line L1 is "240 seconds," and the estimated cycle time 36c on component mounting line L3 is "260 seconds." Also, a "-" stored in the estimated cycle time 36 on any of the component mounting lines L1-L3 indicates that the product type cannot be produced. For example, product type X1 cannot be produced on component mounting line L2.

[0040] That is, the estimated cycle time 36c is the cycle time required to produce the product type in the configuration of the existing component mounting lines L1 to L3 without optimization of the arrangement of the tape feeders 9 and nozzle units 12a, product commonality among a plurality of product types (lots), etc. If there is a removable element required to produce the product type, the estimated cycle time is calculated assuming that the required element is present. If there is production equipment required to produce the product type, the estimated cycle time is calculated only for the component mounting line equipped with that production equipment.

[0041] 5, the production line allocation unit 21b allocates lots (production types) to be produced to production lines (component mounting lines L1 to L3) based on information (production plan information 23a) about the lots (production types) to be produced, such as the estimated cycle time 36 and the number of pieces to be produced 33, and stores the allocation in the production plan information 23a. For example, the production line allocation unit 21b allocates each lot to the component mounting lines L1 to L3 so that there is no bias in the production time of the lot (production type) determined based on the estimated cycle time 36 and the number of pieces to be produced 33. At that time, the production line allocation unit 21b does not allocate the lot (production type) to the component mounting lines L1 to L3 in which production is not possible and for which "-" is stored in the estimated cycle time 36.

[0042] Group creation unit 22a calculates the product commonality between the multiple assigned product types (lots) for each production line (component mounting lines L1 to L3) based on the product type allocation included in production plan information 23a, and groups the multiple product types as groups in which tape feeders 9 and reels 17 are commonly arranged on carts 5 based on the calculated product commonality. Group creation unit 22a stores information related to the groups in production plan information 23a.

[0043] 8, an example of grouping lots A to H (product types X1 to X8) in the production plan information 23a shown in FIG. 6 by the group creation unit 22a will be described. Here, it is assumed that the production line allocation unit 21b has allocated lots A and B (product types X1 and X2) to the component mounting line L1, lots C, D and E (product types X3, X4 and X5) to the component mounting line L2, and lots F, G and H (product types X6, X7 and X8) to the component mounting line L3. The group creation unit 22a calculates the component commonality 37 between the products for each of the component mounting lines L1 to L3.

[0044] In Fig. 8(a), the component commonality 37 between the types X1 and X2 of the lots A and B assigned to the component mounting line L1 is low at "22%," and the group creation unit 22a determines not to group the types X1 and X2. In Fig. 8(b), the component commonality 37 between the types X3 and X4 of the lots C, D, and E assigned to the component mounting line L2 is high at "92%", the component commonality 37 between the types X3 and X5 is high at "80%," and the component commonality 37 between the types X4 and X5 is high at "88%," and the group creation unit 22a determines to group the types X3, X4, and X5.

[0045] In Fig. 8(c), among the lots F, G, and H assigned to the component mounting line L3, the component commonality 37 between the types X6 and X7 is high at "85%," but the component commonality 37 between the types X6 and X8 is "40%," and the component commonality 37 between the types X7 and X8 is low at "36%," so the group creation unit 22a decides to group only the types X6 and X7. Note that in the above description, lots with a component commonality 37 of "80%" or more are grouped together, but this is only an example, and a decision as to whether or not to group them is made based on the value of the component commonality 37 set by the operator. In addition to the decision based on the value, a method of grouping only a set number of lots in descending order of the component commonality 37 from the top to the bottom may also be used.

[0046] 5, the production sequence creation unit 21c creates a production sequence of lots and groups for each of the component mounting lines L1 to L3 and a production sequence of lots belonging to the groups based on information about the assigned production lines and groups included in the production plan information 23a, and stores these in the production plan information 23a. That is, the production sequence creation unit 21c creates a production sequence of the multiple lots (product types) assigned to each of the production lines.

[0047] The equipment configuration determination unit 22b determines the configuration of each production equipment for each lot based on the information on the assigned production line, group, and production sequence included in the production plan information 23a, the product type information 23b, the line configuration information 25a, and the production equipment information 25b, and stores the determined configuration in the production data information 24a. When lots are grouped, the equipment configuration determination unit 22b determines the configuration of the production equipment such that the tape feeders 9 and the reels 17 are commonly arranged on the carts 5 so that lots belonging to the group can be produced without the need to replace the carts 5.

[0048] 5, the cycle time calculation unit 21d calculates the cycle time required to produce a variety including a plurality of lots grouped in the determined configuration of the production equipment for each variety based on the configuration of the production equipment included in the production plan information 23a and the production data information 24a, and stores the cycle time in the cycle time information 23c. The switching time calculation unit 21f calculates the internal setup work time, which is the switching time for changing the configuration of the production equipment in each of the component mounting lines L1 to L3 (production lines) to the next variety, based on the production plan information 23a and the production data information 24a, and stores the cycle time in the switching time information 23d.

[0049] The internal setup work time includes the work of replacing the tape feeders 9 and reels 17 of the carts 5 attached to the component mounting devices M3 to M6 when switching to a product type within the group, and further includes the work time of replacing the carts 5 prepared in the external setup work with the carts 5 attached to the component mounting devices M3 to M6 when switching to a product type outside the group. In addition, the switching time calculation unit 21f calculates the external setup work time required for the external setup work executed in the preparation area As and stores it in the switching time information 23d.

[0050] 5, the production plan update unit 21e updates the production plan based on the cycle time included in the cycle time information 23c, the internal setup work time (switching time) included in the switching time information 23d, and the production plan information 23a. That is, the production plan update unit 21e creates a production plan based on the configuration of production equipment suited to actual production and switching work time without changing the assigned production line, production sequence, or group, and stores the production plan in the production plan information 23a.

[0051] 9(a) shows the updated production plan (production plan information 23a) in chronological order. On component mounting line L1, lots A and B are produced in this production order, and the trolleys 5 are exchanged during the changeover work before the start of production of lots A and B. On component mounting line L2, grouped lots C, D, and E are produced in this production order, and before the start of production of lot C, a changeover work is performed in which a trolley 5 commonly arranged for lots C, D, and E is attached.

[0052] Furthermore, before the start of production of lots D and E, only a changeover operation is performed to replace at least one of the removable elements such as some of the tape feeders 9 and reels 17 mounted on the carts 5 mounted on the component mounting devices M3 to M6, the suction nozzles 12b provided on the component mounting devices M3 to M6, the screen mask provided on the screen printing device M2, the solder paste, etc. Note that there are cases where the changeover operation before the start of production of lots D and E can be omitted.

[0053] In component mounting line L3, grouped lots F and G are produced in this production order, and then lot H is produced. Before the start of production of lot F, a changeover operation is performed to mount a cart 5 commonly arranged for lots F and G, and before the start of production of lot G, only a changeover operation is performed to replace some of the tape feeders 9 and reels 17 mounted on the cart 5 mounted on component mounting devices M3 to M6. Furthermore, in the changeover operation before the start of production of lot H, the cart 5 is replaced.

[0054] 5, the evaluation index value calculation unit 21g calculates an evaluation index value for an updated production plan included in the production plan information 23a and stores it in evaluation index value information 23e. For example, the evaluation index value calculation unit 21g calculates the number of mounting points per hour for each type in the updated production plan and the required number of workers per hour as evaluation index values. In calculating the required number of workers, the evaluation index value calculation unit 21g also calculates the number of people required for off-site setup work in the preparation area As based on the off-site setup work time included in the switching time information 23d.

[0055] The allocation change unit 21h judges whether the evaluation index value included in the evaluation index value information 23e is greater than a predetermined value. If the evaluation index value is less than the predetermined value, the allocation change unit 21h changes the allocation of the product type (lot) to another production line so that the evaluation index value exceeds the predetermined value, and updates the production plan information 23a.

[0056] 5, the delay determination unit 21i determines whether or not there is a product type (lot) whose predicted production end time will be later than the production delivery date 35, based on the production plan information 23a. That is, the delay determination unit 21i determines whether or not there is a product type whose delivery date will be delayed in the production plan. If there is a product type (lot) whose delivery date will be delayed, the allocation change unit 21h changes the allocation of the product type whose delivery date will be delayed to another production line, and updates the production plan information 23a.

[0057] Fig. 9(b) shows a production plan (production plan information 23a) in chronological order after lot B is determined to be delayed in the production plan shown in Fig. 9(a), so the production line for lot B is changed to component mounting line L3 and lot H that was allocated to component mounting line L3 is allocated to component mounting line L1. The production plan shown in Fig. 9(b) has been optimized by the production sequence creation unit 21c and the production plan update unit 21e after the product type allocation was changed.

[0058] That is, the production order on component mounting line L3 has been changed to lot B, followed by grouped lots F and G. Furthermore, the production start time of lot A on component mounting line L1 and the production start time of lot C on component mounting line L2 have been changed so that the product type changeover work that accompanies changing of carts 5 on component mounting lines L1 to L3 does not overlap. This makes it possible to reduce the number of workers required on floor F and improve the evaluation index value.

[0059] Next, a production planning method for creating a production plan for producing a plurality of types of products (mounted boards) on a plurality of production lines (component mounting lines L1 to L3) equipped with production equipment by a management computer 3 (production planning device) will be described along the flow of Fig. 10. First, the approximate cycle time calculation unit 21a calculates the approximate cycle time 36 required to produce each of the plurality of types (lots) on each of the plurality of production lines under optimal conditions based on the production plan information 23a, line configuration information 25a, and production equipment information 25b (ST1: approximate cycle time calculation step).

[0060] Next, the production line allocation unit 21b allocates the types (lots) to be produced to each production line based on the calculated estimated cycle time 36 and the production plan information 23a (ST2: type allocation step). Next, the group creation unit 22a groups the multiple types allocated to each production line based on the product commonality of the multiple types (ST3: group creation step). Next, the equipment configuration determination unit 22b determines the configuration of the production equipment for producing the types (lots) including the grouped production equipment configuration (common arrangement) (ST4: equipment configuration determination step). The determined production equipment configuration is stored as production data information 24a.

[0061] 10, the production sequence creation unit 21c then creates a production sequence for the multiple assigned product types (lots) for each production line (ST5: production sequence creation unit).Then, the cycle time calculation unit 21d calculates the cycle time required to produce each product type including the grouped multiple product types (lots) in the configuration of the production equipment determined in the equipment configuration determination step (ST4) (ST6: cycle time calculation step).

[0062] Next, the switching time calculation unit 21f calculates the switching time (external setup time, internal setup time) for changing the configuration of the production equipment in the production line to the next product type (lot) (ST7: switching time calculation step). Next, the production plan update unit 21e updates the production plan included in the production plan information 23a based on the calculated cycle time and switching time (ST8: production plan update step) (see FIG. 9(a)).

[0063] In Fig. 10, the delay determination unit 21i then determines whether or not there is a product type (lot) that will be delayed in delivery in the updated production plan (ST9: delivery date delay determination step). If there is no delivery date delay (No in ST9), the evaluation index value calculation unit 21g calculates an evaluation index value for the production plan (ST10: evaluation index value calculation step). Next, the allocation change unit 21h determines whether or not the evaluation index value is greater than a predetermined value (ST11: evaluation index value determination step). If the evaluation index value exceeds the predetermined value (Yes in ST11), the production plan stored in the production plan information 23a is determined as the production plan.

[0064] If the evaluation index value is smaller than the predetermined value (No in ST11), the allocation change unit 21h changes the allocation of the product type (lot) to another production line so that the evaluation index value exceeds the predetermined value (ST12: allocation change step). Also, if there is a product type (lot) that will be delayed in the delivery date delay determination step (ST9) (Yes), the allocation change step (ST12) is executed to change the allocation of the product type that will be delayed to another production line.

[0065] When the allocation of product types is changed in the allocation change process (ST12), the process returns to the group creation process (ST3) and the processes up to the production plan update process (ST8) are executed again to update the production plan. After that, a determination is made as to whether a delivery date delay has occurred (ST9) and the evaluation index value is determined (ST10, 11). That is, the production plan is optimized so that a delivery date delay does not occur and the evaluation index value exceeds a predetermined value. Note that if a delivery date delay occurs or the evaluation index value does not exceed the predetermined value even after the optimization loop is repeated a predetermined number of times, the optimization may be terminated and a notification to that effect may be displayed on the display unit 27 of the management computer 3.

[0066] As described above, the production plan creation method of this embodiment can automatically create a production plan with high prediction accuracy and production efficiency. Furthermore, in the process of optimizing the production plan, production data information 24a including the configuration of the production equipment is also automatically created (ST4). That is, the production plan creation method of this embodiment can automatically create a production plan (production plan information 23a) and production data information 24a with high prediction accuracy and production efficiency. This makes it possible to create a production plan with a high evaluation index value and little product type changeover work (external setup work, internal setup work) while meeting the production delivery deadline.

[0067] In addition, in the production method for producing multiple types (lots) of products using multiple production lines equipped with the production equipment of this embodiment, an approximate cycle time is calculated (ST1), the types to be produced are assigned to the production lines (ST2), a production sequence for the types assigned to each production line is created (ST5), and multiple types of products are produced based on the created production sequence. This makes it possible to produce products based on a production plan with high prediction accuracy and production efficiency.

[0068] As described above, the management computer 3 of this embodiment is a production plan creation device that includes an estimated cycle time calculation unit 21a that calculates an estimated cycle time 36 required to produce multiple types (lots) for each production line (component mounting lines L1 to L3), a production line allocation unit 21b that allocates the types to be produced to the production lines based on the estimated cycle time 36 and information on the types to be produced, and a production sequence creation unit 21c that creates a production sequence for the multiple types of products allocated to each production line, and creates a production plan for producing multiple types of products (mounted boards) by multiple production lines equipped with production equipment. This production plan creation device can automatically create a production plan with high prediction accuracy and production efficiency.

[0069] The above description is based on one embodiment of the present invention. It will be understood by those skilled in the art that this embodiment can be modified in various ways in terms of the types and combinations of products produced on the production line, and that such modifications are also within the scope of the present invention. For example, the production line may be an assembly line for assembling electronic devices as products, or a food processing line for manufacturing food products as products. [Industrial Applicability]

[0070] INDUSTRIAL APPLICABILITY The production planning method and production planning device of the present invention have the effect of automatically creating a production plan with high prediction accuracy and production efficiency, and are useful in the field of mounting components on a board. [Explanation of symbols]

[0071] 3. Management computer (production planning device) 12 Mounting head B Substrate L1~L3 Component mounting lines (production lines) M2 Screen printing equipment (printing equipment, production equipment) M3~M6 Component mounting equipment (production equipment)

Claims

1. A production plan creation method for creating a production plan for producing a plurality of types of mounting boards using a plurality of production lines, comprising the steps of: calculating an estimated cycle time required for producing each of the plurality of types of mounting boards on the production line, for each of the production lines; allocating each of the plurality of types of mounting boards to one of the plurality of production lines based on the calculated approximate cycle time; Calculating a cycle time required to produce the allocated type of mounting board on the production line; Create a production plan based on the calculated cycle time; Calculating an evaluation index value for the created production plan; and changing the allocation of the product types to the production lines based on the calculated evaluation index values.

2. grouping the multiple types of mounting boards allocated to the production line, and determining a configuration of production equipment of the production line for producing the multiple grouped types; The cycle time is a time required to produce each of the grouped varieties using the determined configuration of the production equipment; The production planning method according to claim 1 .

3. creating a production sequence for each of the plurality of product types including the plurality of grouped product types for each of the plurality of production lines; Calculating a changeover time required to change the type of product produced on the production line; creating the production plan taking into consideration the calculated switching time; The production planning method according to claim 2 .

4. running an optimization loop after changing the allocation of product types to the production lines; The optimization loop comprises: A step of grouping a plurality of types of mounting boards allocated to the production line; determining a configuration of production equipment of the production line that produces the grouped multiple product types; The production planning method according to any one of claims 1 to 3.

5. The optimization loop comprises: creating a production sequence for each of the plurality of product types including the grouped plurality of product types for each of the plurality of production lines; The production planning method according to claim 4.

6. The evaluation index value is an index related to production efficiency or an index related to human resources required for production; The production planning method according to claim 1 .

7. A production plan creation device that creates a production plan for producing a plurality of types of mounting boards using a plurality of production lines, an approximate cycle time calculation unit that calculates, for each of the production lines, an approximate cycle time required to produce each of the plurality of types of mounting boards on the production line; a production line allocation unit that allocates each of the plurality of types of mounting boards to one of the plurality of production lines based on the calculated approximate cycle time; a cycle time calculation unit that calculates a cycle time required to produce the allocated type of mounting board on the production line; a production plan update unit that creates a production plan based on the calculated cycle time; an evaluation index value calculation unit that calculates an evaluation index value for the created production plan; and an allocation change unit that changes the allocation of the product types to the production lines based on the calculated evaluation index value. Production planning device.

Images