Production capacity estimation system, production capacity estimation method, and production capacity estimation program

Abstract

To provide a production capacity estimation system capable of easily comparing the productivity of a setup work that occurs on component mounting lines with different configurations, a production capacity estimation method, and a production capacity estimation program.SOLUTION: The production capacity estimation method includes the steps of: estimating a setup work that occurs in response to a change of a mounting board to be produced on a component mounting line based on a production plan of the mounting board, a piece of substrate information regarding the configuration of the mounting board, a piece of worker information about the worker who does the setup work, and a piece of floor information for the placement of component mounting lines (ST3); and comparing and displaying the productivity of the setup work estimated in multiple conditions on a display unit (ST4).SELECTED DRAWING: Figure 8

Description

[Technical field]

[0001] The present invention relates to a production capacity estimation system, a production capacity estimation method, and a production capacity estimation program for estimating the production capacity of a component mounting line. [Background technology]

[0002] In a component mounting line consisting of a plurality of component mounting devices including a component mounting device, mounted boards with components mounted on the board are continuously produced. In order to estimate the production capacity of such a component mounting line, in addition to the processing capacity of each component mounting device, it is necessary to take into consideration temporary suspension of the component mounting device due to worker work such as replenishing components and other materials to the component mounting device and responding to errors in the component mounting device (for example, Patent Document 1). It is disclosed that the system described in Patent Document 1 estimates the production capacity of a component mounting line based on pre-stored information such as the configuration of the component mounting line for which production capacity is to be estimated, information on the component mounting devices, and the frequency of worker work, as well as input information on the workers and a production plan. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-199742 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, while conventional technologies including Patent Document 1 can estimate the production capacity of a component mounting line to produce mounted boards, they cannot estimate the productivity of the setup work to change the type of mounted boards produced by the component mounting line, and there is room for further improvement in order to comprehensively estimate the production capacity of a component mounting line.

[0005] Therefore, an object of the present invention is to provide a production capacity estimation system, a production capacity estimation method, and a production capacity estimation program that can easily compare the productivity of setup work that occurs on component mounting lines with different configurations. [Means for solving the problem]

[0006] The production capacity estimation system of the present invention is a production capacity estimation system that estimates setup work that occurs in response to changes in mounted boards produced by a component mounting line composed of a plurality of component mounting devices, and includes a setup work estimation unit that estimates the setup work that will occur based on a production plan for mounted boards produced in the component mounting line, board information related to configurations of the mounted boards, worker information related to workers who perform the setup work, and floor information related to the layout of the component mounting line on the floor, and a display unit that compares and displays the productivity of the setup work estimated under a plurality of conditions.

[0007] The production capacity estimation method of the present invention is a production capacity estimation method for estimating setup work that occurs in response to changes in mounted boards produced by a component mounting line composed of a plurality of component mounting devices, and includes a setup work estimation step of estimating the setup work that will occur based on a production plan for mounted boards produced in the component mounting line, board information related to configurations of the mounted boards, worker information related to workers who perform the setup work, and floor information related to the layout of the component mounting line on the floor, and a display step of comparing the productivity of the setup work estimated under a plurality of conditions and displaying the result on a display unit.

[0008] The production capacity estimation program of the present invention is a production capacity estimation program that causes a computer to execute an estimation of setup work that occurs in response to changes in mounted boards produced by a component mounting line composed of a plurality of component mounting devices, and includes a setup work estimation step of estimating the setup work that will occur based on a production plan for mounted boards produced in the component mounting line, board information related to configurations of the mounted boards, worker information related to workers who perform the setup work, and floor information related to the layout of the component mounting line on the floor, and a display step of comparing the productivity of the setup work estimated under a plurality of conditions and displaying the comparison on a display unit. Effect of the Invention

[0009] According to the present invention, it is possible to easily compare the productivity of setup work occurring in component mounting lines with different configurations. [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 block diagram showing the configuration of an information processing system of a management computer (production capacity estimation system) according to an embodiment of the present invention. [Figure 4] FIG. 2 is an explanatory diagram of an example of a simulation setting screen displayed on a display unit provided in a management computer (production capacity estimation system) according to an embodiment of the present invention; [Diagram 5] FIG. 2 is an explanatory diagram of an example of a simulation result (summary) display screen displayed on the display unit of the management computer (production capacity estimation system) according to an embodiment of the present invention; [Figure 6] FIG. 2 is an explanatory diagram of an example of a simulation result (detailed setup) display screen displayed on a display unit of a management computer (production capacity estimation system) according to an embodiment of the present invention; [Figure 7]FIG. 13 is an explanatory diagram of an example of a simulation result (worker details) display screen displayed on a display unit of a management computer (production capacity estimation system) according to an embodiment of the present invention. [Figure 8] Flow diagram of a production capacity estimation 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 explanation, and can be appropriately changed according to the specifications of the component mounting system, the component mounting line, the management computer (production capacity estimation system), the component mounting device, and the dolly. In the following, the same reference numerals are used for corresponding elements in all the drawings, and duplicated explanations are omitted. In FIG. 2, in the board transport direction (horizontal direction in FIG. 2), the left side of the paper is upstream and the right side is downstream. Also, in FIG. 2, in the direction perpendicular to the board transport direction in the horizontal plane (vertical direction in FIG. 2), the lower side of the paper is the front and the upper side is the rear.

[0012] First, the configuration of the component mounting system 1 will be described with reference to Fig. 1. The component mounting system 1 is configured such that three component mounting lines L1 to L3 arranged on a 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 the floor F. As will be described later, each of the component mounting lines L1 to L3 is configured by connecting a plurality of component mounting devices including a component mounting device, and has the function of producing mounted boards on which components are mounted on a board. Note that the number of component mounting lines L1 to L3 provided in the component mounting system 1 does not need to be three, and two or four or more lines may be used.

[0013] A placement work support device 4 is placed in a preparation area As different from the production area Ap provided on the floor F. The placement work support device 4 is connected to a management computer 3 via a communication network 2. A replacement cart 5 that 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. In addition, the preparation area As stores a plurality of detachable elements, such as masks, feeders, mounting heads, suction nozzles, and reels, that are shared by the component mounting devices arranged on the floor F. The number of placement work support devices 4 placed in the preparation area As does not need to be one, and may be two or more. In addition, the worker W may perform placement work without using the placement work support device 4.

[0014] 1, placement work is performed on a cart 5 connected to a placement work support device 4 according to work instructions corresponding to the types of mounted boards to be produced in component mounting lines L1 to L3. As placement work, a worker W performs work such as removing from the cart 5 a plurality of tape feeders 6 (see FIG. 2) that supply the instructed components and reels that wind and store carrier tapes on which the components are stored, attaching them to instructed positions on the cart 5, and loading the carrier tapes onto the tape feeders 6.

[0015] In other words, in the placement work, the components D are arranged on the carts 5 according to instructions from the placement work support device 4. The placement work can be performed in parallel with the production of mounted boards in the component mounting lines L1 to L3 on the carts 5 in the preparation area As, which includes the carts 5 connected to the placement work support device 4. Hereinafter, the preparation work for switching the type of mounted boards to be produced outside the component mounting lines L1 to L3, which includes the placement work on the carts 5, will be referred to as off-site setup work.

[0016] 1, when switching the type of mounted boards to be produced in the component mounting lines L1 to L3, the worker W carries the cart 5 that has completed placement work in the preparation area As to the component mounting lines L1 to L3 and performs a cart replacement work of replacing it with the cart 5 that is attached to the component mounting device. In addition, in the switching work, the worker W carries materials such as replacement masks, tape feeders 6, tray feeders, mounting heads, suction nozzles, and reels that wind and store carrier tapes containing components, which are stored in the preparation area As, to the component mounting lines L1 to L3 and replace them.

[0017] Hereinafter, the preparation work for switching the type of mounted boards to be produced in the component mounting lines L1 to L3 is referred to as the internal setup work. That is, the internal setup work includes the work of transporting the carts 5, feeders (tape feeders 6, tray feeders), and components (reels that store carrier tapes) from the preparation area As to the production area Ap, the work of replacing the carts 5 mounted on the component mounting devices M3 to M6, the work of replacing the tape feeders 6 arranged on the carts 5 mounted on the component mounting devices M3 to M6, and the work of replacing the components (carrier tapes) supplied by the tape feeders 6 arranged on the carts 5.

[0018] 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 component mounting devices such as a solder printing device M1, a print inspection device M2, component mounting devices M3 to M6, a mounting inspection device M7, and a reflow device M8 in series from upstream (left side of the paper) to downstream (right side of the paper) in the board transport direction. Note that the component mounting line L1 is a group of component mounting devices connected via a communication network 2, and the component mounting devices do not need to be physically connected to each other.

[0019] The solder printer M1, print inspection device M2, component mounting devices M3 to M6, mounting inspection device M7, and reflow device M8 are connected to a management computer 3 via a communication network 2. The solder printer M1 performs a solder printing operation in which solder is printed through a mask having a plurality of openings formed on a board E brought in from upstream by the solder printing operation unit. In the internal setup operation of switching the mounted boards to be produced, a worker W performs operations such as changing the mask and changing the arrangement of the support pins that support the board E from below during solder printing.

[0020] 2, print inspection device M2 performs print inspection work in which a print inspection work unit including a solder inspection camera inspects the state of solder printed on board E. Note that a solder application device that applies solder to board E may be provided in parallel with solder printing device M1 or in place of solder printing device M1. Also, component mounting line L1 does not need to be provided with print inspection device M2.

[0021] In FIG. 2, component mounting devices M3 to M6 perform component mounting work to mount components D on a board E by a component mounting work section including a conveyor, a component supply section, and a mounting head. Note that the component mounting line L1 is not limited to a configuration of four component mounting devices M3 to M6, and may have one to three or five or more component mounting devices M3 to M6. A dolly 5 on which multiple tape feeders 6 are arranged is attached to the component supply section (arrow a). The tape feeder 6 feeds a carrier tape that holds the components D to supply the components D to a pick-up position by the mounting head. Note that the component supply section may also be equipped with a tray feeder that supplies the components D to the pick-up position while switching trays on which multiple components D are placed.

[0022] The mounting head is equipped with a suction nozzle that vacuum-sucks components D, picks up components D supplied by the component supply unit, transports and positions them on the board E held by the conveyor, and performs component mounting work. The tape feeder 6 and tray of the component supply unit are set with carrier tapes and trays that hold predetermined components D so that predetermined components D are supplied according to the type of board to be mounted (in other words, the components D are arranged in predetermined positions).

[0023] In the changeover work, the worker W performs internal setup work such as replacing the carrier tape or tape feeder 6, replacing the tray of the tray feeder, replacing the mounting head, replacing the suction nozzle, and changing the arrangement of the support pins that support the board E from below when mounting components. In addition, the internal setup work of replacing the existing cart 5 with the cart 5 on which the multiple tape feeders 6 are arranged by the external setup work is also performed.

[0024] That is, the setup work for changing the mounted boards produced by the component mounting devices M3 to M6 includes at least one of the work of transporting the cart 5, the work of replacing the cart 5, the work of transporting the feeders (tape feeders 6, tray feeders), the work of replacing the feeders, the work of transporting the components D supplied by the feeders, and the work of replacing the components D (carrier tapes) supplied by the feeders. In this way, the component mounting devices M3 to M6 are component mounting devices on which the cart 5 on which the multiple tape feeders 6 that supply the components D are arranged is mounted, and the mounted boards produced are changed by replacing the mounted cart 5.

[0025] 2, mounting inspection device M7 performs mounting inspection work by inspecting the state of components D mounted on board E using a mounting inspection work section including a component inspection camera. Reflow device M8 performs board heating work by heating board E carried into the device using a board heating section to harden the solder on board E and bond the electrodes of board E to components D. Note that component mounting line L1 does not necessarily have to include mounting inspection device M7.

[0026] Next, the configuration of the information processing system of the management computer 3 will be described with reference to Fig. 3. Here, among the multiple functions of the management computer 3 (production capacity estimation system), the function of estimating the setup work (internal setup work, external setup work) that occurs in response to changes in the component mounting lines L1 to L3 will be described. The management computer 3 includes a processing unit 10, a storage unit 14 as a storage device, an input unit 21, a display unit 22, and a communication unit 23.

[0027] The processing unit 10 is a data processing device such as a CPU, and includes a display processing unit 11, an optimization processing unit 12, a setup operation estimation unit 13, and a control unit (not shown) as internal processing units. Each internal processing unit may be configured with independent hardware assets, or may be configured with a common CPU and a program for each information processing. The control unit is, for example, a CPU (Central Processing Unit), and controls the entire management computer 3. The management computer 3 does not need to be configured with one computer, and may be configured with multiple devices. For example, the memory unit 14 and all or part of the data processing units that configure the management computer 3 may be provided in a cloud via a server.

[0028] 3, input unit 21 is an input device such as a keyboard, a touch panel, a mouse, etc., and is used when inputting operation commands and data. Display unit 22 is a display device such as a liquid crystal panel, and in addition to displaying various data stored in memory unit 14, displays various information such as an operation screen and an input screen for operation by input unit 21. Communication unit 23 is a communication interface, and transmits and receives data via communication network 2 to and from component mounting devices (solder printing device M1, print inspection device M2, component mounting devices M3 to M6, mounting inspection device M7, etc.) that configure component mounting lines L1 to L3.

[0029] 3, storage unit 14 stores production plan information 15, board information 16, production data 17, worker information 18, floor information 19, setup work information 20, etc. Production plan information 15 stores a plurality of production plans, such as production plans for mounted boards that have been produced or will be produced in the future, including the production order of mounted boards (board types) produced on component mounting lines L1 to L3 (or floor F), the scheduled production start time, and the scheduled production end time. Board information 16 stores information on the configuration of the mounted board, such as the size of board E, the mounting positions of components D, and the types of components D, for each board type of mounted board.

[0030] The production data 17 stores, for each type of mounting board, information for identifying the mask to be attached to the solder printing device M1, arrangement information of the support pins, etc. The production data 17 also stores, for each type of mounting board, information on the mounting heads and suction nozzles to be attached to the component mounting devices M3 to M6, arrangement information of the support pins, arrangement of the carriages 5 in the component mounting devices M3 to M6, and arrangement information of the components D including the arrangement of the components D on the carriage 5, etc.

[0031] In Fig. 3, worker information 18 stores information about a worker W who performs setup work, including the type of work permitted to the worker W for each ability category and standard work time. For example, the ability categories of workers W are divided into three ability categories A to C (see Fig. 4). Ability category C is for beginners, and is permitted to carry components such as masks, mounting heads, suction nozzles, carts 5, tape feeders 6, tray feeders, and reels on floor F. Ability category B is for intermediate workers, and is permitted to perform external setup work for carts 5 in preparation area As and internal setup work on component mounting lines L1 to L3. Ability category A is for advanced workers, and is permitted to perform recovery work for errors that occur on component mounting lines L1 to L3.

[0032] Furthermore, the standard work time for each task for an advanced worker in ability category A is shorter than the standard work time for an intermediate worker in ability category B. For example, the standard work time for a part replacement task of replacing a carrier tape supplied to tape feeder 6 is "90 seconds / tape" for an advanced worker in ability category A, whereas it is "120 seconds / tape" for an intermediate worker in ability category B. Note that the number of ability categories, the types of tasks permitted for each ability category, and the standard work time are not limited to those described above and can be changed as appropriate. In this way, worker information 18 includes information regarding the types of setup tasks for which each worker W is responsible.

[0033] 3, floor information 19 stores coordinate information related to the arrangement on floor F, such as the positions of component mounting devices (component mounting devices M3-M6) that make up component mounting lines L1-L3 on floor F, the position of preparation area As, the position of placement work support device 4 installed in preparation area As, the storage position of cart 5, and the position of material storage. In addition to information on existing floor F with production results, floor information 19 also includes information for consideration on new floors where new component mounting lines L1-L3 have been added to increase production capacity of existing floors F, new floors where new component mounting devices have been added to component mounting lines L1-L3, and new floors where the arrangement of preparation area As has been changed.

[0034] Furthermore, the floor information 19 stores information on the materials stored in the preparation area As, etc. That is, the floor information 19 includes the storage position of the cart 5 to be replaced, the storage position of the feeder to be replaced, and the storage position of the part D to be replaced. The display processing unit 11 causes the display unit 22 to display a simulation setting screen and a simulation result display screen, which will be described later, to support the manager in setting conditions and analyzing results for estimating the setup work to be performed on the component mounting lines L1 to L3.

[0035] An example of the simulation setting screen 30 displayed by the display processing unit 11 on the display unit 22 will now be described with reference to Fig. 4. The simulation setting screen 30 is used when setting conditions for an estimation simulation that estimates setup work that occurs on the component mounting lines L1 to L3. In this example, an example will be described in which the component mounting lines L1 to L3 that are the subject of the estimation simulation are set for each floor F on which multiple component mounting lines L1 to L3 are installed.

[0036] The simulation setting screen 30 has a current floor selection frame 31, a current floor display area 31a, a current floor worker setting area 32, a new floor selection frame 33, a new floor display area 33a, a new floor worker setting area 34, a production plan selection frame 35, a production plan display area 35a, an execute button 36, and an end button 37.

[0037] 4, when the administrator operates the input unit 21 to select one existing floor F (hereinafter referred to as the "current floor") to be compared from the drop-down list displayed in the current floor selection frame 31, outline information about the current floor is displayed in the current floor display area 31a. The display processing unit 11 causes the drop-down list of the current floor selection frame 31 to display the existing floor F included in the floor information 19. The display processing unit 11 also causes information about the selected current floor included in the floor information 19 to be displayed in the current floor display area 31a.

[0038] In this example, "Floor F1" is selected as the current floor. In the current floor display area 31a, the line names (lines L1 to L4) of the component mounting lines L1 to L4 set on the current floor and the number of component mounting devices equipped in each line are displayed. When the manager operates the input unit 21 to press the increase / decrease button in the number of people input frame in the current floor worker setting area 32, the number of people is set in the ability category of the workers W to be assigned to the current floor during the estimation simulation. In this example, two advanced workers in ability category A, six intermediate workers in ability category B, and one beginner in ability category C are assigned.

[0039] In Fig. 4, when a new floor F (hereinafter referred to as "new floor") to be compared is selected from the drop-down list in the new floor selection frame 33, outline information about the new floor is displayed in the new floor display area 33a. The display processing unit 11 causes a list of new floors included in the floor information 19 to be displayed in the drop-down list of the new floor selection frame 33. The display processing unit 11 also causes information about the selected new floor included in the floor information 19 to be displayed in the new floor display area 33a.

[0040] In this example, "New Line Addition 1" is selected as the new floor. "New Line Addition 1" is configured by adding a new line L5 to "Floor F1" selected as the current floor. The number of workers to be assigned to the new floor is set in the new floor worker setting area 34. In this example, two advanced workers in ability category A, seven intermediate workers in ability category B, and one beginner in ability category C are assigned.

[0041] 4, when one production plan is selected from the drop-down list in the production plan selection frame 35, outline information about the selected production plan is displayed in the production plan display area 35a. The display processing unit 11 displays a list of production plans included in the production plan information 15 in the drop-down list of the production plan selection frame 35. The display processing unit 11 also displays information about the selected production plan included in the production plan information 15 in the production plan display area 35a. In this example, "Existing production plan 1", which has a production record on "Floor F1", is selected as the production plan.

[0042] In the production plan display area 35a, the board types and production quantities of the mounted boards that are set to be produced on the current floor and the new floor in the estimated simulation of the setup work are displayed in the order of production. In "Existing production plan 1", it is planned to produce 500 mounted boards X1, 2000 mounted boards X2, 1500 mounted boards X3, 800 mounted boards X4, etc. in this order.

[0043] 4, when the manager operates the input unit 21 to press the execute button 36, an estimation simulation is executed by the optimization processing unit 12 and the setup operation estimating unit 13 to estimate a setup operation based on the conditions set on the simulation setting screen 30. When the end button 37 is pressed, the display processing unit 11 discards the conditions set on the simulation setting screen 30 and ends the setting process of the estimated simulation conditions.

[0044] 3, the optimization processing unit 12 executes optimization processing to allocate workers W and mounted boards to the component mounting line on the current floor and the component mounting line on the new floor so as to reduce the amount of setup work that occurs. The optimization processing unit 12 optimizes the allocation of mounted boards, production order, and allocation of workers W so as to reduce the number of setup operations and the operating time of workers W while observing the production delivery deadline of each mounted board (board type) and under conditions where there is little bias in the operation rate of the component mounting line. In addition, the optimization processing unit 12 changes (or creates new) production data 17 based on the optimized allocation of mounted boards to the component mounting lines and the production order, i.e., the optimized production plan.

[0045] As described below, the setup work estimation unit 13 estimates the setup work to be performed on the current floor and the new floor based on the production plan and production data 17 optimized by the optimization processing unit 12, the allocation of the current floor, the new floor, and the workers W set by the process of setting the estimated simulation conditions, and the board information 16, the worker information 18, and the floor information 19 stored in the storage unit 14. That is, the setup work estimation unit 13 estimates the setup work under multiple conditions of the current floor and the new floor. The conditions of the current floor and the new floor include the configuration of multiple component mounting devices provided in the component mounting line, the number of component mounting lines arranged on the floor F, the production order of the mounted boards, the production time of the mounted boards, the number of workers W, and the like. The setup work estimated by the setup work estimation unit 13 is stored in the storage unit 14 as setup work information 20.

[0046] Next, an example of a simulation result display screen in which the display processing unit 11 displays the results of the estimated simulation by the setup work estimation unit 13 on the display unit 22 will be described with reference to Fig. 5 to Fig. 7. Fig. 5 is an example of a simulation result (summary) screen 40 that the display processing unit 11 displays on the display unit 22. The simulation result (summary) screen 40 displays a summary of the estimated simulation results included in the setup work information 20, and is displayed on the display unit 22 when the execute button 36 is pressed on the simulation setting screen 30 (Fig. 4) and a setup work is estimated by the setup work estimation unit 13.

[0047] 5, a simulation result (summary) screen 40 is provided with a summary display area 41, a setup details display button 42, a worker details display button 43, a condition change button 44, and an end button 45. The summary display area 41 displays the total results of the setup work estimated to occur on the component mounting line, including the number of setup parts, the number of setup carts, the number of resource carts, the number of workers, and worker hours, for the current floor and the new floor, as well as a comparison result in which the current floor is the comparison source and the new floor is the comparison target.

[0048] The number of setup parts is the total number of times that the parts supplied by the tape feeder 6 arranged on the trolley 5 are replaced in the external setup work and the internal setup work. The number of setup trolleys is the total number of replacement trolleys 5 on which the parts supplied by the tape feeder 6 are replaced in the external setup work. The number of resource trolleys is the total number of trolleys 5 attached to the component mounting devices on the component mounting line and the trolleys 5 stored in the preparation area As, that is, the total number of trolleys 5 arranged on the floor. The number of workers is the total number of workers W assigned to the floor. The worker hours is the total operating time during which the workers W assigned to the floor are performing setup work (internal setup work, external setup work).

[0049] In Fig. 5, the estimated simulation results for the current floor are estimates for the case where nine workers W are assigned to the current floor (Floor F1) with four component mounting lines, and production is carried out according to a proven production plan (Existing Production Plan 1). Also, the estimated simulation results for the new floor are estimates for the case where ten workers W are assigned to the new floor (New Line Addition 1) with five component mounting lines, and production is carried out according to a proven production plan (Existing Production Plan 1). In other words, in the estimated simulation for the new floor, mounted boards produced on the four component mounting lines are optimally assigned to the five component mounting lines.

[0050] The estimated simulation results for the current floor are 2,271 setup parts, 75 setup carts, 57 resource carts, 9 workers, and 294 hours, 28 minutes, and 48 seconds of worker time.The estimated simulation results for the new floor are 2,481 setup parts, 114 setup carts, 83 resource carts, 10 workers, and 353 hours, 31 minutes, and 12 seconds of worker time.In addition, a comparison of the current floor and the new floor shows a 9.2% increase in the number of setup parts, a 52.0% increase in the number of setup carts, a 45.6% increase in the number of resource carts, an 11.1% increase in the number of workers, and a 20.0% increase in worker time.

[0051] In Fig. 5, when the setup details display button 42 is pressed, the display processing unit 11 causes the display unit 22 to display a simulation result (setup details) screen 50 (Fig. 6). When the worker details display button 43 is pressed, the display processing unit 11 causes the display unit 22 to display a simulation result (worker details) screen 60 (Fig. 7). When the condition change button 44 is pressed, the display processing unit 11 causes the display unit 22 to display the simulation setting screen 30 (Fig. 4). When the end button 45 is pressed, the display processing unit 11 ends the setup work estimation process.

[0052] 6, an example of a simulation result (setup details) screen 50 displayed by the display processing unit 11 on the display unit 22 will be described. The simulation result (setup details) screen 50 displays details of information related to the number of setup tasks among the estimated simulation results included in the setup task information 20. The simulation result (setup details) screen 50 is provided with a summary display area 51, a summary graph display area 52, a cart count designation button 52a, a part count designation button 52b, a current floor detail display area 53, a new floor detail display area 54, a summary display button 55, a worker detail display button 56, a condition change button 57, and an end button 58.

[0053] The current floor detail display area 53 displays the number of external setup operations, the number of setup carts, the number of setup parts for external setup operations, the number of internal setup operations, and the number of setup parts for internal setup operations for each component mounting line (lines L1 to L4) on the current floor. For example, for line L1, 469 parts are replaced using nine carts 5 in one external setup operation, and nine parts are replaced in six internal setup operations.

[0054] In FIG. 6, the current floor detail display area 53 displays the total number of setup parts for external setup work and internal setup work for each component mounting line. For example, in line L1, the number of setup parts for external setup work is 469, and the number of setup parts for internal setup work is 9, for a total of 478. The current floor detail display area 53 also displays the total number for the current floor, which is the sum of the numerical values ​​for each component mounting line by type. For example, the number of external setup work is 1 time for line L1, 1 time for line L2, 4 times for line L3, and 2 times for line L4, for a total of 8 times for the current floor. The new floor detail display area 54 displays numerical values ​​similar to those displayed in the current floor detail display area 53 for the new floor, and detailed explanations will be omitted.

[0055] 6, summary display area 51 displays the total values ​​for each type as a floor summary from the numerical values ​​displayed in current floor detail display area 53 and new floor detail display area 54. That is, summary display area 51 displays the number of external setup operations, the number of internal setup operations, the number of setup carts, the number of setup parts for external setup operations, the number of setup parts for internal setup operations, and the total number of setup parts for external setup operations and the number of setup parts for internal setup operations for the current floor and the new floor.

[0056] Summary graph display area 52 displays a graph comparing the numerical values ​​of the current floor and the new floor displayed in summary display area 51. In Fig. 6, a graph comparing the number of setup tasks (external setup tasks, internal setup tasks) is displayed in summary graph display area 52. When cart number designation button 52a is pressed, a graph comparing the number of setup carts is displayed in summary graph display area 52. Furthermore, when part number designation button 52b is pressed, a graph comparing the number of setup parts (number of setup parts for external setup tasks, number of setup parts for internal setup tasks) is displayed in summary graph display area 52.

[0057] In Fig. 6, when the summary display button 55 is pressed, the display processing unit 11 causes the display unit 22 to display the simulation result (summary) screen 40 (Fig. 5). When the worker detail display button 56 is pressed, the display processing unit 11 causes the display unit 22 to display the simulation result (worker detail) screen 60 (Fig. 7). When the condition change button 57 is pressed, the display processing unit 11 causes the display unit 22 to display the simulation setting screen 30 (Fig. 4). When the end button 58 is pressed, the display processing unit 11 ends the estimation process for the setup work.

[0058] 7, an example of a simulation result (worker details) screen 60 displayed by the display processing unit 11 on the display unit 22 will be described. The simulation result (worker details) screen 60 displays details of information relating to the work time of worker W and the like from among the estimated simulation results included in the setup work information 20. The simulation result (worker details) screen 60 has a summary display area 61, a number of people graph display area 62, a worker utilization rate graph display area 63, a time details display area 64, a summary display button 65, a setup details display button 66, a condition change button 67, and an end button 68.

[0059] The summary display area 61 displays the number of workers W assigned to the current floor and the new floor for each division of the type of setup work they are responsible for, and the worker utilization rate. The summary display area 61 also displays the total number of workers W on the current floor and the new floor and a comparison thereof, and the worker utilization rate on the current floor and the new floor and a comparison thereof. The worker utilization rate is the proportion of the working time during which the worker W performs setup work out of the total working hours. In this example, the divisions of the types of setup work they are responsible for are divided into five divisions: "line assignment (for each line)", "line (all lines)", "external setup", "materials transport", and "all lines / external setup / materials transport". Hereinafter, the five divisions of responsibility will be referred to as divisions P to T, respectively.

[0060] In FIG. 7, worker W in responsibility category P is assigned to the line and is responsible for the internal setup work of each component mounting line. Worker W in responsibility category Q is responsible for the internal setup work of all component mounting lines on the current floor or new floor. Worker W in responsibility category R is responsible for the external setup work in the preparation area As. Worker W in responsibility category S is responsible for transporting parts between the preparation area As and the component mounting lines. Worker W in responsibility category T is responsible for the internal setup work, external setup work, and transporting parts of all component mounting lines. Note that the number of responsibility categories and the allocation of setup work to each responsibility category are not limited to the above and can be changed as appropriate.

[0061] The number of workers graph display area 62 displays a graph comparing the number of workers W on the current floor and the new floor displayed in the summary display area 61. The worker availability graph display area 63 displays a graph comparing the worker availability rates on the current floor and the new floor displayed in the summary display area 61 for each of the work categories P to T.

[0062] 7, the time detail display area 64 displays the working hours of worker W, the working time during which setup work is being performed, the non-working time during which setup work is not being performed, and the worker operation rate for the current floor and the new floor for each of the responsibility categories P to T. The time detail display area 64 also displays the total working hours, working time, and non-working time for each of the current floor and the new floor, the worker operation rates for the current floor and the new floor, and a comparison of these between the current floor and the new floor.

[0063] For example, the current floor's assigned category P has four workers W, and the total working hours for the four workers is 288 hours, of which 187 hours 12 minutes are in operation and 100 hours 48 minutes are off, resulting in a worker utilization rate of 65%. The operating hours for the current floor are 187 hours 12 minutes for assigned category P with four workers, 20 hours 9 minutes 36 seconds for assigned category Q with one worker, 24 hours 28 minutes 48 seconds for assigned category R with one worker, 10 hours 48 minutes for assigned category S with one worker, and 51 hours 50 minutes 24 seconds for assigned category T with two workers, resulting in a total of 294 hours 28 minutes 48 seconds for the current floor, resulting in a worker utilization rate of 45%. The total operating hours for the current floor are 294 hours 28 minutes 48 seconds for nine workers, and the total operating hours for the new floor are 353 hours 31 minutes 12 seconds for ten workers, resulting in a 20.0% increase in the total operating hours for the new floor compared to the current floor.

[0064] When the summary display button 65 is pressed, the display processing unit 11 causes the display unit 22 to display the simulation result (summary) screen 40 (FIG. 5). When the setup detail display button 66 is pressed, the display processing unit 11 causes the display unit 22 to display the simulation result (setup detail) screen 50 (FIG. 6). When the condition change button 67 is pressed, the display processing unit 11 causes the display unit 22 to display the simulation setting screen 30 (FIG. 4). When the end button 68 is pressed, the display processing unit 11 ends the setup work estimation process.

[0065] In this way, the display unit 22 displays the estimated productivity of the setup work, such as the number of workers W performing setup work, the time during which the workers W perform setup work (working time), the time during which the workers W are not performing setup work (non-working time), and the ratio of the time during the working hours of the workers W during which setup work is performed (worker operating rate), comparing the current floor with the new floor, i.e., under multiple conditions. This makes it possible to easily compare the productivity of setup work occurring on component mounting lines with different configurations.

[0066] Next, an example of optimization processing by the optimization processing unit 12 and an estimation simulation processing by the setup operation estimation unit 13 will be described with reference to Fig. 3 and Fig. 4 to Fig. 7. In Fig. 3, the optimization processing unit 12 executes optimization processing to allocate workers W of the current floor and workers W of the new floor, which are set by the setting processing, to five responsibility categories P to T.

[0067] Here, the optimization process of the allocation of the workers W will be specifically described with reference to FIG. 4 and FIG. 7. In FIG. 4, two advanced workers in ability category A, six intermediate workers in ability category B, and one beginner in ability category C are set as the workers W on the current floor. In FIG. 7, the optimization processing unit 12 first assigns one beginner who is only permitted to carry materials to the responsibility category S in charge of carrying materials only. Next, the optimization processing unit 12 assigns the advanced workers who work quickly (short standard work time) to the responsibility category R and the responsibility category T in charge of the external setup work, one each. Next, the optimization processing unit 12 assigns four intermediate workers to the responsibility category P. That is, one intermediate worker is assigned to each of the four component mounting lines equipped on the current floor. Next, the optimization processing unit 12 assigns the remaining two intermediate workers to the responsibility category Q and the responsibility category T.

[0068] In FIG. 3 , the setup operation estimation unit 13 executes an estimation simulation process to estimate the number of setup operations based on the production order and production time of mounted boards for each component mounting line included in the production plan optimized by the optimization processing unit 12, the arrangement information of components D of the component mounting device for each board type included in the production data 17, and the information of the replacement trolleys 5 included in the floor information 19.

[0069] Here, the estimation simulation process for estimating the number of setup operations will be specifically described with reference to Fig. 6. The setup operation estimation unit 13 determines the number of external setup operations and the number of setup carts based on the number of replacement carts 5 and the difference in arrangement information of the components D before and after the setup operation of the component mounting device equipped in each component mounting line. Next, the setup operation estimation unit 13 determines the number of setup components for the external setup operation and the replacement order of the components D (carrier tape) based on the difference in arrangement information of the components D before and after the external setup operation of the replacement cart 5. Next, the setup operation estimation unit 13 determines the number of internal setup operations, the number of setup components for the internal setup operation and the replacement order of the components D (carrier tape) based on the difference in arrangement information of the components D before and after the internal setup operation of the cart 5 that is attached to the component mounting device and is not replaced.

[0070] Next, the setup operation estimation unit 13 executes an estimation simulation process to estimate the operation time (operation time) of the setup operation based on the determined replacement order of parts D (carrier tape), information on workers W assigned to the responsibility categories P to T (see FIG. 7), standard operation times included in worker information 18, and coordinate information on the arrangement on floor F included in floor information 19. Specifically, the setup operation estimation unit 13 calculates and adds up operation times (operation times) such as travel time and replacement time for each operation order such as replacement of parts D (carrier tape) for each worker W.

[0071] For example, in the task of transporting a cart 5 on which external setup work has been completed from the preparation area As, the setup work estimation unit 13 calculates the movement time from the distance from the preparation area As to the component mounting device and the movement speed of the worker W. In addition, in the task of replacing a component D (carrier tape) supplied by the tape feeder 6, the setup work estimation unit 13 calculates the work time by adding together the standard work time for removing the carrier tape from the tape feeder 6 and the standard work time for attaching the carrier tape to the tape feeder 6.

[0072] Next, a production capacity estimation method (production capacity estimation program) for estimating the setup work occurring in response to changes in mounted boards produced by component mounting lines L1-L3 composed of multiple component mounting devices will be described along the flow of Fig. 8. First, a production plan (production plan information 15) for mounted boards produced by component mounting lines L1-L3, board information 16 relating to the configuration of the mounted boards, worker information 18 relating to workers W who perform the setup work, and floor information 19 relating to the arrangement of component mounting lines L1-L3 on floor F are acquired (ST1: information acquisition step).

[0073] Next, the optimization processing unit 12 optimizes the allocation of mounting boards to the component mounting lines L1 to L3 arranged on the floor F, the production order, and the allocation of the workers W based on the acquired information so as to reduce the number of setup operations and the working hours of the workers W (ST2: optimization step). Next, the setup operation estimation unit 13 estimates the setup operations that will occur in the component mounting lines L1 to L3 based on the acquired information and the optimized information (ST3: setup operation estimation step). Next, the display processing unit 11 compares the productivity of the setup operations estimated under a plurality of conditions and displays them on the display unit 22 (ST4: display step) (e.g., Figs. 5 to 7). This makes it possible to easily compare the productivity of the setup operations that will occur in component mounting lines with different configurations.

[0074] When estimating the setup work again by changing conditions such as the configuration of the floor F and the component mounting lines L1-L3, the layout of the component mounting lines L1-L3 and the preparation area As on the floor F, the production plan, and the allocation of the workers W (No in ST5), the information acquisition process (ST1) to the display process (ST4) are repeatedly executed. At that time, the simulation setting screen 30 (FIG. 4) and the like are used to input and change the conditions of the estimation simulation.

[0075] As described above, the management computer 3 of this embodiment is a production capacity estimation system that includes a setup work estimation unit 13 that estimates the setup work to be generated based on the production plan (production plan information 15) of the mounted boards produced in the component mounting lines L1 to L3 composed of multiple component mounting devices, board information 16 related to the configuration of the mounted boards, worker information 18 related to the workers W who perform the setup work, and floor information 19 related to the arrangement of the component mounting lines L1 to L3 on the floor F, and a display unit 22 that compares and displays the productivity of the setup work estimated under multiple conditions, and estimates the setup work to be generated in response to changes in the mounted boards produced by the component mounting lines L1 to L3. This makes it possible to easily compare the productivity of the setup work generated in component mounting lines with different configurations. [Industrial Applicability]

[0076] The production capacity estimation system, production capacity estimation method, and production capacity estimation program of the present invention have the effect of making it possible to easily compare the productivity of setup work that occurs on component mounting lines with different configurations, and are useful in the field of mounting components onto boards. [Explanation of symbols]

[0077] 3. Management computer (production capacity estimation system) 5 Carts 6 Tape feeder (feeder) D parts L1~L3 Component mounting lines M3~M6 Component mounting equipment (component mounting equipment) W Worker

Claims

1. A production capacity estimation system that estimates a setup operation that occurs in response to a change in a mounted board produced by a component mounting line composed of a plurality of component mounting devices, comprising: a setup work estimation unit that estimates the setup work to be performed based on a production plan for mounted boards to be produced in the component mounting line, board information relating to a configuration of the mounted boards, worker information relating to workers who perform the setup work, and floor information relating to an arrangement on a floor of the component mounting line; A display unit that compares and displays the productivity of the setup work estimated under a plurality of conditions.

2. the component mounting device includes a component mounting device in which a carriage having a plurality of feeders arranged thereon for supplying components is mounted, and a mounted board to be produced is changed by replacing the carriage to be mounted; 2. The production capacity estimation system according to claim 1, wherein the estimated setup work includes at least one of the work of transporting the cart, the work of replacing the cart, the work of transporting the feeder, the work of replacing the feeder, the work of transporting a part supplied by the feeder, and the work of replacing the part supplied by the feeder.

3. 3. The production capacity estimation system according to claim 2, wherein the setup operation estimation unit further estimates the setup operation to be performed based on production data including an arrangement of the carriages and an arrangement of the components in the component mounting device.

4. 4. The production capacity estimation system according to claim 2, wherein the floor information includes at least one of a storage location of the carriage to be replaced, a storage location of the feeder to be replaced, and a storage location of the part to be replaced.

5. The production capacity estimation system according to claim 1 , wherein the worker information includes information regarding the type of the setup work that each of the workers is in charge of.

6. 6. The production capacity estimation system according to claim 1, wherein the productivity of the setup work includes at least any one of the number of the workers performing the setup work, the time during which the workers are performing the setup work, the time during which the workers are not performing the setup work, and the proportion of the time during which the workers are performing the setup work in their working hours.

7. 7. The production capacity estimation system according to claim 1, wherein the conditions include at least any of a configuration of the plurality of component mounting devices equipped in the component mounting line, a number of the component mounting lines arranged on the floor, a production sequence of the mounted boards, a production time of the mounted boards, and a number of the workers.

8. A production capacity estimation method for estimating a setup operation that occurs in response to a change in a mounted board produced by a component mounting line composed of a plurality of component mounting devices, comprising: a setup work estimation step of estimating the setup work to be performed based on a production plan for mounted boards to be produced in the component mounting line, board information relating to a configuration of the mounted boards, worker information relating to workers who perform the setup work, and floor information relating to an arrangement on a floor of the component mounting line; and a display step of comparing the productivity of the setup work estimated under a plurality of conditions and displaying the comparison result on a display unit.

9. A production capacity estimation program that causes a computer to estimate a setup operation that occurs in response to a change in a mounted board produced by a component mounting line composed of a plurality of component mounting devices, comprising: a setup work estimation step of estimating the setup work to be performed based on a production plan for mounted boards to be produced in the component mounting line, board information relating to a configuration of the mounted boards, worker information relating to workers who perform the setup work, and floor information relating to an arrangement on a floor of the component mounting line; and a display step of comparing the productivity of the setup work estimated under a plurality of conditions and displaying the comparison result on a display unit.

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