Maintenance device and maintenance method

Abstract

The present invention provides a maintenance management device and maintenance management method that can appropriately guide information regarding the replacement of units. [Solution] A maintenance management method for a unit used in a mounting device involves obtaining a plan for periodic maintenance to be performed based on the usage time or number of times the unit is used in the mounting device (ST1), determining a first period from the periodic maintenance plan that is the time to perform periodic maintenance on a unit before it reaches the end of its lifespan and is the time when the unit should be replaced (ST3), and determining whether or not to notify information regarding the replacement of a unit that should be replaced before a predetermined time (preparation time) starting from the first period, based on maintenance information including the determined unit to be replaced, the number of spare units that can be replaced, and the time required to prepare for the replacement of the unit to be replaced (preparation time) (ST5).

Description

Technical Field

[0001] The present disclosure relates to a maintenance management device and a maintenance management method for managing the maintenance of units used in production equipment.

Background Art

[0002] Production equipment included in a component mounting line for producing mounting substrates has units such as tape feeders, heads, and nozzles attached thereto. These units are maintained by the maintenance time determined by the usage period, the number of uses, etc. in order to suppress the deterioration of accuracy and the increase in the error rate due to use.

[0003] Patent Document 1 discloses that, based on the allowable value of the available time or number of uses of a unit and the production plan, when the usage time or number of uses of the unit during production exceeds the allowable value, the unit is maintained or replaced before the production start switching time. More specifically, if the maintenance of the unit is completed within the scheduled switching time, the maintenance is performed at the switching time, and if the maintenance is not completed within the switching time, the unit is replaced with a spare unit. According to Patent Document 1, it is possible to prevent the delay of the production plan due to maintenance.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, while prior art, including Patent Document 1, can prevent delays in the production schedule by replacing units that do not complete maintenance within the scheduled changeover time with spare units, there is a problem that production schedules may be delayed if there are no spare units available at the changeover time or if workers cannot be secured to perform the replacement work at the changeover time.

[0006] Therefore, the purpose of this disclosure is to provide a maintenance management device and a maintenance management method that can appropriately guide information regarding the replacement of a unit. [Means for solving the problem]

[0007] The maintenance management device of this disclosure has a processing unit that obtains a plan for periodic maintenance to be performed based on the usage time or number of times the unit is used in the production equipment from a planning device that plans maintenance for units used in the production equipment, determines a first period from the periodic maintenance plan which is the time when the periodic maintenance to be performed on the unit before it reaches the end of its life and is the time when the unit should be replaced, and determines whether or not to notify information regarding the replacement of the unit that should be replaced before a predetermined time starting from the first period, based on maintenance information including the number of spare units that can be replaced with the determined unit to be replaced and the time required to prepare for the replacement of the unit to be replaced.

[0008] The maintenance management method of this disclosure is a maintenance management method for a unit used in a production apparatus, which involves obtaining a plan for periodic maintenance to be performed based on the usage time or number of times the unit is used in the production apparatus, determining a first period from the periodic maintenance plan that is the time when the periodic maintenance to be performed on the unit before it reaches the end of its lifespan and is the time when the unit should be replaced, and determining whether or not to notify information regarding the replacement of the unit to be replaced before a predetermined time, starting from the first period, based on maintenance information including the number of spare units that can be replaced with the unit to be replaced and the time required to prepare for the replacement of the unit to be replaced. [Effects of the Invention]

[0009] According to this disclosure, information regarding the replacement of the unit can be appropriately provided. [Brief explanation of the drawing]

[0010] [Figure 1] Diagram illustrating the configuration of a component mounting system according to one embodiment of the present disclosure. [Figure 2] Plan view showing the configuration of the main part of the mounting device included in a component mounting system of one embodiment of the present disclosure. [Figure 3] Diagram illustrating the configuration of a mounting device included in a component mounting system according to one embodiment of the present disclosure. [Figure 4] Block diagram showing the configuration of a component mounting system in one embodiment of the present disclosure. [Figure 5] Diagram illustrating an example of maintenance information used in a management device according to one embodiment of this disclosure. [Figure 6] An explanatory diagram illustrating an example of the first time period and preparation time determined in a control device according to one embodiment of the present disclosure. [Figure 7] An explanatory diagram illustrating an example of the first time period and preparation time determined in a control device according to one embodiment of the present disclosure. [Figure 8] An explanatory diagram illustrating an example of the first time period and preparation time determined in a control device according to one embodiment of the present disclosure. [Figure 9] An explanatory diagram illustrating an example of a unit ordering instruction screen displayed on a display unit connected to a management device in one embodiment of the present disclosure. [Figure 10] Flowchart of a maintenance management method according to one embodiment of this disclosure [Figure 11] Flowchart of a method for determining preparation time according to one embodiment of the present disclosure [Modes for carrying out the invention]

[0011] An embodiment of this disclosure will be described in detail below with reference to the drawings. The configurations, shapes, etc. described below are illustrative examples for illustrative purposes and can be modified as appropriate according to the specifications of the component mounting system, management device, planning device, mounting device, unit, etc. In the following, all corresponding elements are denoted by the same reference numerals in all drawings, and redundant explanations are omitted. In Figure 2 and some parts described later, the X-axis in the substrate transport direction (left-right direction in Figure 2) and the Y-axis in the substrate transport direction (up-down direction in Figure 2) are shown as two mutually orthogonal axes in the horizontal plane. In Figure 3 and some parts described later, the Z-axis (up-down direction in Figure 3) is shown as the height direction perpendicular to the horizontal plane.

[0012] First, the configuration of component mounting system 1 will be explained with reference to Figure 1. Component mounting system 1 is configured by connecting three mounting devices M1 to M3 and a management device 3 via a communication network 2. Component mounting system 1 has the function of producing mounted boards by sequentially passing boards and mounting components onto them using mounting devices M1 to M3. Mounting devices M1 to M3 are production devices that mount components onto boards to produce mounted boards. Note that the mounting devices M1 to M3 in component mounting system 1 do not necessarily have to be three; there may be one, two, or four or more.

[0013] The management device 3 functions as a line management device that comprehensively controls the mounting devices M1 to M3, as well as a maintenance management device that manages the replacement of units used in the mounting devices M1 to M3. The management device 3 is connected to a planning device 4 that plans maintenance for units used in the production equipment, including the mounting devices M1 to M3. The planning device 4 transmits the created maintenance plan to the management device 3. Note that the planning device 4 does not need to be directly connected to the management device 3. For example, the planning device 4 may be connected to a communication network 2 and the maintenance plan may be transmitted through the communication network 2. Alternatively, the management device 3 may be configured to have the maintenance plan creation function of the planning device 4.

[0014] Next, referring to FIGS. 2 and 3, the configurations of the mounting devices M1 to M3 will be described. The mounting devices M1 to M3 have the same configuration, and here, the mounting device M1 will be described as an example. The mounting device M1 has a function of performing a component mounting operation for producing a mounting substrate by mounting the components supplied from the component supply unit onto the substrate. In the center of the base 5, a substrate transfer mechanism 6 is arranged along the X-axis. The substrate transfer mechanism 6 includes a transfer conveyor 6a, which transfers the substrate B conveyed from the upstream to the mounting operation position, positions it, and holds it. Further, the substrate transfer mechanism 6 discharges the substrate B for which the component mounting operation has been completed downstream. The transfer conveyor 6a is detachable from the substrate transfer mechanism 6.

[0015] On both sides of the substrate transfer mechanism 6 (in the front-rear direction of the Y-axis), component supply units 7 are arranged. In each component supply unit 7, a carriage 9 on which a plurality of tape feeders 8 are arranged along the X-axis is set. On the carriage 9, a reel 11 that stores the carrier tape 10 formed with pockets for accommodating the components D in a wound state is held. The tape feeder 8 supplies the component D to the component extraction position 8a where the component D is taken out by the head 14 described below by pitch-feeding the carrier tape 10 drawn out from the reel 11 in the direction from the outside of the component supply unit 7 toward the substrate transfer mechanism 6 (tape feeding direction). The tape feeder 8 is detachable from the carriage 9.

[0016] In FIGS. 2 and 3, on both ends of the upper surface of the base 5 in the X-axis direction, Y-axis tables 12 provided with linear drive mechanisms are arranged along the Y-axis. On the Y-axis table 12, a beam 13 similarly provided with a linear drive mechanism is movably coupled along the Y-axis. The beam 13 is arranged along the X-axis. On the beam 13, a head 14 is mounted movably along the X-axis via a plate 13a. The head 14 is detachable from the plate 13a. Below the head 14, a nozzle 15 for adsorbing and holding the component D is mounted. The head 14 raises and lowers the nozzle 15 and rotates it around the Z-axis. The nozzle 15 is detachable from the head 14.

[0017] The Y-axis table 12 and the beam 13 constitute a head movement mechanism 16 that moves the head 14 along the X-axis and Y-axis. The head movement mechanism 16 and the head 14 perform a mounting cycle of adsorbing and taking out the component D from the tape feeder 8 arranged in the component supply unit 7 by the nozzle 15 and mounting it at the mounting position of the substrate B held by the substrate transfer mechanism 6. The head movement mechanism 16 is detachable from the base 5.

[0018] In FIGS. 2 and 3, a component recognition camera 17 is arranged between the component supply unit 7 and the substrate transfer mechanism 6. When the head 14 that has taken out the component D from the component supply unit 7 moves above the component recognition camera 17, the component recognition camera 17 images the component D held by the nozzle 15. From the captured image, the position deviation of the component D held by the nozzle 15, the holding posture of the component D, etc. are recognized. The component recognition camera 17 is detachable from the base 5. A head camera 18 is attached to the plate 13a to which the head 14 is attached. The head camera 18 moves integrally with the head 14. The head camera 18 is detachable from the plate 13a.

[0019] When the head 14 moves, the head camera 18 moves above the substrate B held by the substrate transfer mechanism 6 and images a substrate mark (not shown) provided on the substrate B. From the captured image, the position of the substrate B with respect to the substrate transfer mechanism 6 is recognized. In the component mounting operation on the substrate B by the head 14, the mounting position is corrected in consideration of the recognition result of the component D based on the captured image of the component recognition camera 17 and the recognition result of the substrate position based on the captured image of the head camera 18.

[0020] In FIG. 2, a touch panel 19 operated by the operator is installed at the position where the operator works on the front surface of the mounting apparatus M1. The touch panel 19 displays various information on its display unit, and the operator inputs data and operates the mounting apparatus M1 using operation buttons and the like displayed on the display unit.

[0021] The conveyor belt 6a, tape feeder 8, head 14, nozzle 15, head movement mechanism 16, part recognition camera 17, and head camera 18 used in the mounting equipment M1 to M3 (production equipment) are units U that undergo maintenance such as cleaning and adjustment according to the maintenance plan, and are also replaced.

[0022] Next, with reference to Figure 4, the configuration of the component mounting system 1 will be described. Here, the description will mainly focus on the configuration related to its function as a maintenance management system for managing the maintenance of unit U used in mounting devices M1 to M3 (production equipment). Hereafter, the unit U subject to maintenance will also include replacement parts that make up unit U, such as valves (head valves) used in head 14.

[0023] In Figure 4, the control unit 20 of the mounting devices M1 to M3 is connected to a substrate transport mechanism 6, a tape feeder 8, a head 14, a head movement mechanism 16, a component recognition camera 17, a head camera 18, a touch panel 19, and the like. The control unit 20 controls each part based on the stored production program to perform the component mounting operation, which involves mounting components D to the mounting positions on the substrate B.

[0024] Furthermore, the control unit 20 measures the usage time, number of uses (number of times the tape feeder 8 supplies parts, number of times the head 14's nozzle moves up and down, number of times the nozzle 15 picks up parts, etc.), and usage amount (transport distance of the transport conveyor 6a, drive distance of the head movement mechanism 16, etc.) of the units U (units used) used in the mounting devices M1 to M3 during the parts mounting work, and transmits the measurement data Da, which shows the measurement results, to the management device 3. This measurement data Da includes the measurement results (usage time, number of uses, usage amount) for each of the multiple units U (units used) used in the mounting devices M1 to M3.

[0025] Furthermore, the control unit 20 aggregates the number of errors that occurred during component mounting work using unit U, based on the detection results of various sensors provided by the mounting devices M1 to M3, and transmits error data Db, which includes the number of errors, to the management device 3. This error data Db is the number of errors for each of the multiple unit U (units used) used in the mounting devices M1 to M3. The aggregated errors include at least one of the following: component supply errors in which the tape feeder 8 fails to supply component D, component suction errors in which the nozzle 15 fails to properly hold component D, component recognition errors, and component mounting errors in which the component fails to properly mount on the substrate.

[0026] Furthermore, the control unit 20 may associate the results of the inspection machine's determination of the mounting status of the components (such as poor mounting status) on the mounted circuit board with the components mounted on it with the unit U, tally up the number of defective components, which is the number of components related to the unit U that had a poor mounting status, and transmit the error data Db, which includes the number of defective components, to the management device 3.

[0027] In Figure 4, the management device 3 comprises a storage unit 21, a processing unit 25, and a communication unit 31. A display unit 32, such as a monitor, is connected to the processing unit 25. The communication unit 31 is a communication interface and transmits and receives various types of information between the management device 3 and the implementation devices M1 to M3 via the communication network 2. The communication unit 31 is also connected to the planning device 4 and transmits and receives various types of information between the management device 3 and the planning device 4.

[0028] The planning device 4 includes a maintenance plan creation unit 33. The maintenance plan creation unit 33 acquires the usage time or number of uses of unit U in the mounting devices M1 to M3 (production devices), and creates a maintenance plan for periodic maintenance to be performed based on the usage time or number of uses for each unit U (target unit) to be maintained. In addition, the maintenance plan creation unit 33 creates a maintenance plan so that maintenance of the target unit is performed at the timing when the type of mounting board to be produced is changed, based on the production plan of the mounted board. The maintenance plan creation unit 33 transmits the created maintenance plan for the target unit to the management device 3.

[0029] In Figure 4, the memory unit 21 of the management device 3 is a storage device that stores various types of information. The memory unit 21 is implemented, for example, by flash memory or an HDD (Hard Disk Drive). The memory unit 21 stores information such as maintenance plans 22, unit usage information 23, and maintenance information 24. The maintenance information 24 includes replacement unit information 24a, preparation time information 24b, and tolerance value information 24c. The tolerance value information 24c stores tolerance values ​​for production-related indicators of unit U (see Figure 8).

[0030] In a specific example, as shown in Figure 8, for tape feeder 8 (feeder A), which is unit U, the production-related indicator shows the error rate, and the tolerance value shows the tolerance value for the error rate (error rate tolerance value). The unit U being used (unit in use) is replaced with a new unit U (replacement unit) before the production-related indicator exceeds the tolerance value.

[0031] Here, with reference to Figure 5, an example of replacement unit information 24a and preparation time information 24b included in maintenance information 24 will be explained. Maintenance information 24 includes, for each unit name 40, the number of spares 41, procurement time 42, replacement time for in-house work 43, slack time for work by other companies 44, replacement time for work by other companies 45, design limit time and design limit number of times. The unit name 40 is information that identifies unit U, such as the model number of unit U. The number of spares 41 is the number of spare unit U units remaining after deducting the number of allocated unit U units that have been decided to be replaced with the unit in use from the number of unit U units in stock that can be replaced with the unit U being used (unit in use). Replacement unit information 24a includes the unit name 40 and the number of spares 41.

[0032] Procurement time 42 is the average time from ordering unit U from the manufacturer or distributor until it is available. In-house replacement time 43 is the average time required when the in-house workers perform the task of replacing the used unit (unit U to be replaced) with the replacement unit (new unit U). Other-party work buffer time 44 is the average time required (other-party worker procurement time) from the time the replacement work is requested to another company's workers until the replacement work can be performed. Other-party replacement time 45 is the average time required when another company's workers perform the task of replacing the used unit with the replacement unit. Preparation time information 24b includes unit name 40, procurement time 42, in-house replacement time 43, other-party work buffer time 44, and other-party replacement time 45.

[0033] The design limit time and design limit cycles are the period and number of cycles that the manufacturer or vendor can guarantee the usability of Unit U, and are generally recommended values ​​determined by the manufacturer or vendor.

[0034] Thus, the maintenance information 24 includes the number of spare units U (replacement units) that can be replaced with the unit U (unit in use) (spare unit number 41), and the time required to prepare for the replacement of the unit U to be replaced (preparation time information 24b). The maintenance information 24 also includes information on the allocated spare units U that can be replaced with the unit in use and that have been decided to be replaced with the unit in use.

[0035] In Figure 4, the processing unit 25 of the management device 3 is a processing unit such as a CPU. Based on the stored program, the processing unit 25 executes a plan acquisition process 26, a quality information acquisition process 27, a first timing determination process 28, a preparation time determination process 29, a judgment process 30, and so on. The processing unit 25 acquires the plan for periodic maintenance of the unit U (target unit) to be maintained from the planning device 4 and executes a plan acquisition process 26 to store it in the storage unit 21 as a maintenance plan 22. The maintenance plan 22 includes the periodic maintenance timings Tm1 to Tm5 (see Figures 6 to 8), which are the scheduled timings for periodic maintenance planned for the unit U to be maintained, as timing information 22a.

[0036] The processing unit 25 executes data acquisition processing to obtain measurement data Da and error data Db from the mounting devices M1 to M3. In a specific example, the measurement data Da to be acquired shows the usage time, number of uses, and amount used of the tape feeder 8, which is unit U. The error data Db to be acquired shows the number of errors in the tape feeder 8, which is unit U.

[0037] In Figure 4, the processing unit 25 executes a unit usage information calculation process to calculate unit usage information 23 based on the acquired measurement data Da and error data Db. The calculated unit usage information 23 includes the cumulative usage time, cumulative number of uses, cumulative usage amount, and quality information of unit U. Note that the unit usage information 23 does not need to include all of the cumulative usage time, cumulative number of uses, and cumulative usage amount; it is sufficient to include at least one of them. In this embodiment, the cumulative number of uses is used as an example, but the same applies to cumulative usage time and cumulative usage amount.

[0038] In the unit usage information calculation process, the processing unit 25 calculates production-related indicators at the time of calculating the unit usage information 23 based on the measurement data Da and the error data Db. The production-related indicators are indicators related to the production of mounted boards, such as the error rate and the defect rate. The error rate is, for example, the ratio of the number of errors to the number of times the nozzle 15 picked up components from the tape feeder 8, which is unit U, in order to produce one type of mounted board. The defect rate is, for example, the ratio of the number of defects to the number of components supplied from the tape feeder 8, which is unit U, in order to produce one type of mounted board, in order to produce one type of mounted board.

[0039] In Figure 4, during the unit usage information calculation process, the processing unit 25 accumulates the number of uses shown in the measurement data Da from the start date of use (when unit U was first used in component mounting work) to the time of calculating the unit usage information 23. Then, the processing unit 25 executes a quality information calculation process to calculate quality information based on the accumulated number of uses and the calculated production-related indicators. The quality information shows the trend of how the production-related indicators of unit U change in relation to the cumulative number of uses of unit U.

[0040] In a specific example, as shown in Figure 8, the processing unit 25 calculates the actual value of the number of uses C1 as the unit usage information 23 for the first periodic maintenance period Tm1. Next, the processing unit 25 calculates quality information based on the calculated cumulative number of uses (number of uses C1) and the production-related indicators of unit U at the time when the cumulative number of uses of unit U reaches the number of uses C1. Then, the processing unit 25 stores the cumulative number of uses (number of uses C1, current cumulative number of uses) and the quality information as the unit usage information 23.

[0041] Thus, the processing unit 25 executes a quality information acquisition process 27 that calculates (acquires) quality information and stores it as usage unit information 23. The usage unit information 23 includes cumulative usage time, cumulative number of uses, cumulative usage amount, and quality information for each of the multiple units U (used units) used in the mounting devices M1 to M3. The usage unit information 23 may include the cumulative number of uses at multiple points in time, or it may include the cumulative number of uses at the time of the most recent periodic maintenance, or the current cumulative number of uses.

[0042] In Figure 4, the processing unit 25 executes a first timing determination process 28 that determines the first timing (periodic maintenance timings Tm1 to Tm5) in the periodic maintenance plan, which is the timing when periodic maintenance should be performed on the unit U before its cumulative usage time or cumulative number of uses reaches its lifespan, such as the design limit time or design limit number of uses, and is the timing when the unit U should be replaced. This timing is determined based on the timing information 22a of the maintenance plan 22 and the unit usage information 23.

[0043] Here, with reference to Figure 6, a first embodiment of the first timing determination process 28 by the processing unit 25 will be described. Figure 6 is an XY graph in which time is shown on the horizontal axis and the number of times the unit U to be maintained is used is shown on the vertical axis. The same applies to Figures 7 and 8, which will be described later.

[0044] Maintenance plan 22 schedules periodic maintenance for five periodic maintenance periods Tm1 to Tm5. The current time is between the completion of the second periodic maintenance and the execution of the third periodic maintenance (between periodic maintenance period Tm2 and periodic maintenance period Tm3). In the first embodiment, it is predicted that the number of uses will not exceed the design limit before the unit U (unit in use) to be replaced reaches the design limit time. The design limit time is between periodic maintenance period Tm4 and periodic maintenance period Tm5. In this case, the processing unit 25 determines periodic maintenance period Tm4, in which the fourth periodic maintenance immediately preceding the design limit time is scheduled, as the first period (first period determination process 28).

[0045] In Figure 4, the processing unit 25 executes a preparation time determination process 29 to determine the time required to prepare for the replacement of the unit U (unit used) to be replaced, based on the unit usage information 23, the replacement unit information 24a and the preparation time information 24b of the maintenance information 24. If the replacement work is performed by the company's own workers, the processing unit 25 determines the time required from instructing the workers to perform the replacement work until the replacement work is possible (preparation time) to be zero (0). In other words, the procurement time for the company's own workers is zero (0). If the replacement work is requested from another company's workers, the processing unit 25 determines the slack time 44 of the other company's work (procurement time for the other company's workers) as the preparation time.

[0046] Furthermore, if there is stock of replacement units, i.e., the number of spares 41 is "1 or more", the processing unit 25 will not change the determined preparation time. Similarly, if there is no stock of replacement units, i.e., the number of spares 41 is "0", and the procurement time 42 is less than or equal to the preparation time (slack time 44 for other companies' work), the processing unit 25 will not change the determined preparation time. On the other hand, if there is no stock of replacement units, and the procurement time 42 is longer than the preparation time, the processing unit 25 will change (determine) the procurement time 42 of the replacement unit to the preparation time. Note that even if the number of spares 41 is "0", if a spare unit U has already been assigned to the unit U to be maintained, the processing unit 25 will not change the determined preparation time (slack time 44).

[0047] In other words, even if the replacement work is performed by an employee of the company, if there is no stock of replacement units, the processing unit 25 determines the preparation time to be the procurement time 42 for the replacement unit. Also, if the replacement work is performed by an employee of another company, the processing unit 25 determines the preparation time to be the longer of the buffer time 44 (procurement time for the employee of the other company) and the procurement time 42 for the replacement unit. That is, in the preparation time information 24b of the maintenance information 24, the time required to prepare for the replacement of the unit U (unit in use) to be replaced (preparation time) differs depending on the employee (of the company or another company) who replaces the unit U to be replaced.

[0048] In Figure 4, the processing unit 25 executes a decision process 30 to determine whether or not to notify information regarding unit U (unit in use) that should be replaced before the preparation time (predetermined time), starting from the first period (periodic maintenance period Tm1 to Tm5). The information to be notified includes instructions for replacement work to the company's own workers (in-house replacement work instructions), requests for replacement work to other companies' workers (other company replacement work request instructions), and orders for unit U (unit order instructions). If it takes time to procure replacement units or other companies' workers, the processing unit 25 decides to notify the information before the first period in which instructions for replacing unit U are given. In other words, the processing unit 25 decides to notify the information before the preparation time required to procure replacement units or other companies' workers, starting from the first period.

[0049] In Figure 4, if the processing unit 25 determines that it is necessary to notify information, it will notify the display unit 32 of the information. Alternatively, the processing unit 25 will notify the information to an information terminal held by the company's workers. For example, if the replacement of unit U (used unit) to be replaced is to be carried out by another company's workers, the processing unit 25 will instruct them to notify the information (instruction to request replacement work from another company) before the preparation time (predetermined period) starting from the first time. Also, if the replacement of unit U to be replaced is to be carried out by the company's workers, the processing unit 25 will instruct them to notify the information (instruction to perform replacement work at the company) at the first time.

[0050] If there is a shortage of spare units U (replacement units) (the number of spares 41 is "0"), the processing unit 25 will instruct the system to notify information (unit ordering instructions) before the preparation time (a predetermined time) starting from the first period. The processing unit 25 will determine that the preparation time (a predetermined time) is the same as, or longer than, the time (procurement time 42) from which it becomes possible to replace the unit U that needs replacing (the unit in use) after ordering the spare unit U. Unit U that is approaching its design limit time or design limit number of cycles (lifespan) may fail suddenly before reaching its lifespan. By ordering replacement units with ample margin beyond the procurement time 42 and keeping replacement units in stock, it is possible to quickly replace a unit U in use even if it fails suddenly. This prevents the problem of production of mounted boards being stopped for a long time due to a shortage of replacement units.

[0051] Here, with reference to Figure 6, an example of the preparation time determination process 29 by the processing unit 25 will be explained. In this example, the unit U to be maintained is the head movement mechanism 16. The number of spare head movement mechanisms 16 41 is "0", and there is no stock of replacement units. The procurement time 42 is "20 days". Also, the replacement time 43 for in-house work is "-", meaning in-house work is not possible. Therefore, the replacement work will be outsourced. The replacement time 45 for work by the other company is "6.0 hours", and the buffer time 44 is "3 days". Since the procurement time 42 (20 days) is longer than the buffer time 44 (3 days), the processing unit 25 determines the procurement time 42 (20 days) as the preparation time (preparation time determination process 29).

[0052] In this example, the time prior to the preparation time, starting from the first period (periodic maintenance period Tm4), is before the scheduled third periodic maintenance (periodic maintenance period Tm3). The processing unit 25 decides to notify information regarding the unit U to be replaced (unit order instruction) at the present time (before the preparation time, starting from the first period) (decision processing 30). The processing unit 25 also notifies information to perform the work of cleaning the head movement mechanism 16 during the third periodic maintenance (periodic maintenance period Tm3). Furthermore, the processing unit 25 notifies information to perform the work of replacing the head movement mechanism 16 with a replacement unit (other company replacement work instruction) during the fourth periodic maintenance (periodic maintenance period Tm4).

[0053] Here, with reference to Figure 9, an example of the unit order instruction screen 50 displayed on the display unit 32 by the processing unit 25 will be explained. In this example, the replacement time for head 14 (unit in use) with management number "A123" is approaching, but there is no stock of the replacement unit, head 14 with model number "H18", so the processing unit 25 has issued a unit order instruction. The unit order instruction screen 50 displays information identifying the unit U (unit in use) to be replaced (management number of head 14) and information about the replacement unit to be ordered (model number of head 14). In this example, the unit order instruction screen 50 also displays the scheduled replacement date (first period) as reference information.

[0054] Next, with reference to Figure 7, a second embodiment of the first timing determination process 28 by the processing unit 25 and an example of the preparation time determination process 29 will be described. In the second embodiment of the first timing determination process 28, it is predicted that the number of uses will exceed the design limit before the unit U (used unit) to be replaced reaches the design limit time before the periodic maintenance period Tm5. That is, it is predicted that the number of uses will exceed the design limit between periodic maintenance periods Tm3 and Tm4. In this case, the processing unit 25 determines the third periodic maintenance immediately before the design limit is exceeded (periodic maintenance period Tm3) as the first timing (first timing determination process 28).

[0055] In this example, the unit U to be maintained is the head valve. The number of spare head valves (41) is "2", and there is stock of replacement units. It has also been decided to request the replacement work to be outsourced. The replacement time (45) for the work to be done by the other company is "1.0 hour", and the buffer time (44) is "3 days". The processing unit 25 determines that the replacement time (3 days) is the preparation time because there is stock of replacement units and the work will be done by another company (preparation time determination process 29). Furthermore, the processing unit 25 determines that the second scheduled maintenance (scheduled maintenance period Tm2) is planned before the time when the instruction to request the replacement work from the other company should be notified, and therefore does not notify the instruction to request the replacement work from the other company at this time, and allocates one of the stock of replacement units to be used as a replacement head valve for the unit U to be maintained (decision process 30).

[0056] Next, with reference to Figure 8, a third embodiment of the first timing determination process 28 by the processing unit 25 and an example of the preparation time determination process 29 will be described. In the third embodiment of the first timing determination process 28, the first timing is determined based on the quality information contained in the unit usage information 23. In this example, the time progression of the error rate is used as the quality information. The error rate is displayed on the second vertical axis of the XY graph.

[0057] In the example shown in Figure 8, it is predicted that the number of uses will not exceed the design limit before the unit U (unit in use) to be replaced reaches its design limit time. On the other hand, it is predicted that the error rate will exceed the allowable error rate before the unit in use reaches its design limit time. That is, it is predicted that the error rate will exceed the allowable error rate between periodic maintenance periods Tm3 and Tm4. In this case, the processing unit 25 determines the third periodic maintenance immediately before the error rate exceeds the allowable error rate (periodic maintenance period Tm3) as the first period (first period determination process 28).

[0058] Thus, as a first timing determination process 28, the processing unit 25 determines the timing of periodic maintenance (periodic maintenance timing Tm3) for unit U (unit in use) before the production-related indicator reaches the acceptable value, based on the quality information (error rate relative to the cumulative number of uses) contained in the unit usage information 23 and the acceptable value (error rate tolerance) of the production-related indicator (error rate) contained in the tolerance value information 24c, as the first timing.

[0059] In other words, the processing unit 25 calculates quality information based on the cumulative number of uses (number of uses C1 in Figure 8) and the actual values ​​of the production-related indicator (error rate) of unit U during that cumulative number of uses. Then, the processing unit 25 calculates a predicted value for the cumulative number of uses during the period of scheduled maintenance to be performed from now on (scheduled maintenance period Tm2 to Tm5). Based on the predicted cumulative number of uses and the quality information, the processing unit 25 calculates a predicted value for the production-related indicator (error rate) of unit U and compares the time when the predicted value of the production-related indicator (error rate) exceeds the allowable value (error rate tolerance) with the design limit time. If the processing unit 25 determines that the predicted value of the production-related indicator (error rate) of unit U exceeds the allowable value (error rate tolerance) before the design limit time, it determines the scheduled maintenance immediately before the error rate tolerance is exceeded (scheduled maintenance period Tm3 in Figure 8) as the first period.

[0060] In Figure 8, in this example, the unit U to be maintained is feeder A. The number of spare feeder A units 41 is "10", and replacement units are in stock. It has also been decided that the replacement work will be performed in-house. The replacement time 43 for in-house work is "0.1 hours". The processing unit 25 determines that the preparation time is zero (0) because replacement units are in stock and the work will be performed in-house (preparation time determination process 29).

[0061] In the example shown in Figure 8, the tape feeder 8 was used as an example. However, instead of the tape feeder 8, the conveyor belt 6a, tape feeder 8, head 14, nozzle 15, head movement mechanism 16, part recognition camera 17, and head camera 18 can also be similarly configured. Based on the quality information included in the unit usage information 23, the tolerance values ​​of production-related indicators included in the tolerance value information 24c, the design limit time included in the maintenance information 24, and the timing of periodic maintenance included in the maintenance plan 22, the timing of periodic maintenance immediately before the predicted value of the production-related indicator exceeds the tolerance value can be determined as the first periodic maintenance period.

[0062] Furthermore, the processing unit 25 instructs the company to notify the company of the replacement work instructions at the first time (periodic maintenance period Tm3) because the replacement of feeder A is to be performed by the company's own workers (decision processing 30). Also, the processing unit 25 allocates one of the replacement unit stocks to feeder A for replacement of unit U, which is subject to maintenance (decision processing 30).

[0063] Next, following the flow in Figure 10, the maintenance management method for unit U used in mounting equipment M1 to M3 (production equipment) by the maintenance management device (management device 3) will be explained. First, the processing unit 25 acquires a plan for periodic maintenance (maintenance plan 22) based on the usage time or number of times unit U is used in mounting equipment M1 to M3 (production equipment) (ST1: maintenance plan acquisition process). Then, the processing unit 25 acquires quality information showing the trend of changes in production-related indicators of unit U (ST2: quality information acquisition process).

[0064] Next, the processing unit 25 determines the first time from the acquired periodic maintenance plan (periodic maintenance periods Tm1 to Tm5) that is the time to perform periodic maintenance on the unit U before it reaches the end of its lifespan and that is the time when the unit U should be replaced (ST3: first time determination process). Next, the processing unit 25 determines the preparation time required to prepare for the replacement of the unit U (unit in use) to be replaced (ST4: preparation time determination process).

[0065] In Figure 10, the processing unit 25 then determines whether or not to notify information regarding the replacement of the unit U to be replaced before a predetermined time (preparation time) starting from the first time, based on the maintenance information 24 which includes the determined unit U to be replaced (unit in use), the number of spare units U that can be replaced (41 spares), and the preparation time required to prepare for the replacement of the unit U to be replaced (ST5: determination step). If it determines to notify (Yes in ST5), the processing unit 25 causes the display unit 32 to notify information regarding the replacement of the unit U (unit order instruction, instruction to request replacement work from another company, instruction to perform replacement work in-house) (ST6: notification step).

[0066] Next, the preparation time determination process (ST4) (preparation time determination method) will be explained in detail according to the flow in Figure 11. First, the processing unit 25 determines whether the replacement work is an in-house operation or not (ST11: In-house operation determination process). If it is an in-house operation (Yes in ST11), the processing unit 25 determines the preparation time to be zero (0) (ST12). If it is not an in-house operation, i.e., if it is an operation by another company (No in ST11), the processing unit 25 determines the slack time 44 for the operation by the other company as the preparation time (ST13). Next, the processing unit 25 determines whether there is a spare replacement unit based on the number of spares 41 (ST14: Spare unit determination process).

[0067] If there are no spare replacement units (No in ST14), the processing unit 25 determines whether the procurement time 42 is longer than the preparation time determined in (ST12) or (ST13) (ST15). If the procurement time 42 is longer than the preparation time (Yes in ST15), the processing unit 25 determines the procurement time 42 to be the preparation time (ST16). If there are spare replacement units (Yes in ST14), or if the procurement time 42 is less than or equal to the preparation time (No in ST15), the preparation time determined in (ST12) or (ST13) is not changed.

[0068] The above explanation of the maintenance and management of unit U uses mounting devices M1-M3 as an example of production equipment, but the production equipment is not limited to mounting devices M1-M3. For example, the production equipment could be a printing device that screen prints solder paste onto substrate B, a printing inspection device that uses a camera to inspect the solder printed on substrate B, or a mounting inspection device that uses a camera to inspect components D mounted on substrate B. In that case, the unit U would consist of components such as a conveyor belt, camera, and squeegee that are replaced.

[0069] As explained above, this disclosure discloses the following technical concepts.

[0070] (Technology 1) From the planning device 4, which plans maintenance for units used in production equipment (mounting devices M1-M3), a plan for periodic maintenance to be performed based on the usage time or number of times the unit was used in the production equipment is obtained (plan acquisition process 26). Among the regular maintenance plans, the first period is determined as the time when regular maintenance should be performed on unit U before it reaches the end of its lifespan (regular maintenance periods Tm1 to Tm5), and the time when unit U should be replaced (first period determination process 28). A maintenance management device (management device 3) has a processing unit 25 that determines whether or not to notify information regarding the replacement of a unit U to be replaced before a predetermined time (preparation time) starting from a first period (decision processing 30), based on maintenance information 24 which includes the determined unit U to be replaced, the number of spare unit Us that can be replaced (spare number 41), and the time required to prepare for the replacement of the unit U to be replaced (preparation time).

[0071] This allows for proper guidance regarding the replacement of unit U.

[0072] (Technology 2) Processing unit 25 is, If there is a shortage of spare units U, instructions will be given to notify the information before a predetermined time (preparation time) starting from the first period. The maintenance management device (management device 3) described in Technical 1 determines the predetermined time to be the same as, or longer than, the time required from ordering a spare unit U until it becomes possible to replace it with the unit U that needs replacing (procurement time 42).

[0073] This allows us to properly provide information regarding ordering a spare unit U before replacing the unit U itself.

[0074] (Technology 3) In maintenance information 24, the time required to prepare for the replacement of unit U (preparation time) varies depending on the worker performing the replacement of unit U. Processing unit 25 is, If the replacement of unit U to be replaced is to be carried out by a worker from another company, instructions will be given to notify the company of the information before the designated time (preparation time), starting from the first period. If the replacement of unit U to be replaced is to be carried out by the company's own workers, the maintenance management device (management device 3) described in Technical 1 or 2 will instruct them to notify the company of the information at the first stage.

[0075] This allows for appropriate guidance regarding the replacement of spare unit U, depending on whether the replacement is performed by an employee of the same company or another company.

[0076] (Technology 4) Processing unit 25 is, We obtain quality information that shows the trend of changes in production-related indicators for unit U in relation to the number of times unit U is used. Based on quality information and tolerance values ​​for production-related indicators (tolerance information 24c), A maintenance management device (management device 3) according to any one of technologies 1 to 3, which determines the timing of periodic maintenance for unit U before production-related indicators reach acceptable values ​​as the first period.

[0077] This allows for proper guidance regarding the replacement of spare unit U, ensuring that the quality of the mounted circuit board does not deteriorate.

[0078] (Technology 5) A method for maintaining and managing unit U used in production equipment (mounting equipment M1 to M3), Obtain a schedule for periodic maintenance based on the usage time or number of times Unit U is used in the production equipment (ST1), In the regular maintenance plan, determine the first period (ST3) when regular maintenance should be performed on unit U before it reaches the end of its lifespan, and when unit U should be replaced. A maintenance management method (ST5) that determines whether or not to notify information regarding the replacement of a unit U to be replaced before a predetermined time (preparation time) starting from a first period, based on maintenance information 24 which includes the unit U to be replaced (unit in use), the number of spare units U that can be replaced (spare number 41), and the time required to prepare for the replacement of the unit U to be replaced (preparation time).

[0079] This allows for proper guidance regarding the replacement of unit U. [Industrial applicability]

[0080] The maintenance device and maintenance method of this disclosure have the effect of being able to appropriately provide information regarding the replacement of units and are useful in the field of mounting components onto a circuit board. [Explanation of Symbols]

[0081] 3 Management device (maintenance management device) 4. Planning device M1-M3 Mounting Equipment (Production Equipment) U Unit

Claims

1. A planning device that plans maintenance for units used in production equipment obtains a schedule for periodic maintenance to be performed based on the usage time or number of times the unit is used in the production equipment. Of the aforementioned periodic maintenance plan, a first period is determined which is the time when the periodic maintenance should be performed on the unit before it reaches the end of its lifespan, and which is the time when the unit should be replaced. A maintenance management device having a processing unit that determines whether or not to notify information regarding the replacement of a unit to be replaced before a predetermined time, starting from the first time, based on maintenance information including the number of spare units that can be replaced and the number of units to be replaced that have been determined, and the time required to prepare for the replacement of the unit to be replaced.

2. The aforementioned processing unit, If there is a shortage of spare units, the system will instruct the system to notify the information before the predetermined time, starting from the first time period. The maintenance management device according to claim 1, wherein the predetermined time is determined to be the same as, or longer than, the time required from ordering a spare unit until it becomes possible to replace the unit to be replaced.

3. In the aforementioned maintenance information, the time required to prepare the unit to be replaced varies depending on the worker performing the replacement. The aforementioned processing unit, If the replacement of the unit to be replaced is to be carried out by an employee of another company, instructions will be given to notify the employee of the information before the predetermined time, starting from the first time period. The maintenance management device according to claim 1, which provides guidance to notify the company of the information at the first time if the replacement of the unit to be replaced is to be performed by the company's own workers.

4. The aforementioned processing unit, Quality information is obtained that shows the trend of changes in production-related indicators of the unit in relation to the number of times the unit is used. Based on the aforementioned quality information and the tolerance values ​​of the production-related indicators, The maintenance management device according to claim 1, wherein the timing of the periodic maintenance on the unit before the production-related indicator reaches the tolerance value is determined as the first timing.

5. A method for maintaining and managing units used in production equipment, A plan for periodic maintenance to be performed on the unit based on the usage time or number of times it was used in the production equipment is obtained. Of the aforementioned periodic maintenance plan, a first period is determined which is the time when the periodic maintenance should be performed on the unit before it reaches the end of its lifespan, and which is the time when the unit should be replaced. A maintenance management method that determines whether or not to notify information regarding the replacement of a unit to be replaced before a predetermined time, starting from the first time, based on maintenance information including the number of spare units that can be replaced and the number of units to be replaced that have been determined, and the time required to prepare for the replacement of the unit to be replaced.

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