Production planning method, production planning system, and production planning program

Abstract

To provide a production planning method, a production planning system, and a production planning program that can create the next production plan on the basis of the current status of a component mounting line.SOLUTION: A production planning method acquires the current configuration of a component mounting device in a component mounting line (ST12), acquires information on the target production type to be produced in the future (ST13), calculates the similarity rate between the target production type and the production type that can be produced with the current configuration of the component mounting device (ST15), and creates a production plan that assigns the target production type to the component mounting line on the basis of the similarity rate (ST16).SELECTED DRAWING: Figure 12

Description

Technical Field

[0001] The present invention relates to a production plan creation method, a production plan creation system, and a production plan creation program for creating a production plan for producing mounting substrates of a plurality of product types by a component mounting line.

Background Art

[0002] When producing products such as mounting substrates on which components are mounted by a plurality of production lines equipped with production facilities, a production plan including the allocation of product types to each production line and the production order is created so that a plurality of product types can produce a predetermined production volume by a predetermined production due date. Further, in each production line, production data including the configuration of production facilities according to the product type to be produced is created. When creating production data, the configuration of production facilities is created so that the setup change for changing the configuration of production facilities due to a change in product type is reduced.

[0003] By the way, in a production line, production data cannot be created unless a production plan is created and the product type to be produced is determined. On the contrary, unless the production data is determined, the accurate time required for producing the product type cannot be calculated and a highly accurate production plan cannot be created. That is, the production plan and the production data have a circular reference relationship, and in order to create a production plan and production data with high prediction accuracy and production efficiency at the same time, a highly skilled creator needs to spend a long time creating them. Patent Document 1 describes a system for assisting the creator's creation work when creating a production plan and production data (processing process plan) at the same time.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Incidentally, when creating a production plan, for a plurality of production lines currently producing products, it may be necessary to create a production plan and production data for a plurality of product types to be produced next. However, in the prior art including the system described in Patent Document 1, the current production situation is not taken into account, the quality of the production plan and production data created depends on the skills of the operator, and there is a problem that the time required for the creation work increases exponentially as the number of product types to be produced increases.

[0006] Therefore, an object of the present invention is to provide a production plan creation method, a production plan creation system, and a production plan creation program capable of creating a next production plan from the current situation of a component mounting line.

Means for Solving the Problems

[0007] The production plan creation method of the present invention is a production plan creation method for creating a production plan for producing mounting substrates of a plurality of production product types by a component mounting line including a component mounting device for mounting components supplied by a component supply device on a substrate, wherein the production plan assigns a plurality of production product types to a plurality of component mounting lines, and includes a step of acquiring the current configuration of component mounting devices provided in the plurality of component mounting lines, a step of acquiring information on production product types to be produced from now on, a step of calculating a similarity rate between the production product types to be produced from now on and the production product types that can be produced in the current configuration of the component mounting devices, and a step of creating a production plan in which the production product types to be produced from now on are assigned to any one of the plurality of component mounting lines based on the similarity rate.

[0008] The production plan creation system of the present invention is a production plan creation system for producing mounting substrates of a plurality of production types by a plurality of component mounting lines each including a component mounting device for mounting components supplied by a component supply device on a substrate. The system includes a similarity rate calculation unit that calculates a similarity rate between the production type to be produced and the production types that can be produced in the current configuration of the component mounting device based on the current configuration of the component mounting device provided in the component mounting line and information on the production type to be produced, and a production plan creation unit that creates a production plan in which the production type to be produced is assigned to any one of the plurality of component mounting lines based on the similarity rate.

[0009] The production plan creation program of the present invention is a production plan creation program that causes a computer to execute the creation of a production plan for producing mounting substrates of a plurality of production types by a plurality of component mounting lines each including a component mounting device for mounting components supplied by a component supply device on a substrate. The program includes steps of acquiring the current configuration of the component mounting device provided in the component mounting line, acquiring information on the production type to be produced, calculating a similarity rate between the production type to be produced and the production types that can be produced in the current configuration of the component mounting device, and creating a production plan in which the production type to be produced is assigned to any one of the plurality of component mounting lines based on the similarity rate.

Advantages of the Invention

[0010] According to the present invention, the next production plan can be created based on the current situation of the component mounting line.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Embodiments for Carrying Out the Invention

[0012] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. The configurations, shapes, etc. described below are illustrative for explanation purposes, and can be appropriately changed according to the specifications of the component mounting system, component mounting line, management computer, component mounting device, etc. In the following, corresponding elements in all the drawings are denoted by the same reference numerals, and duplicate explanations are omitted. In FIG. 3, and in part of the description below, as two axial directions orthogonal to each other in the horizontal plane, the X direction in the substrate conveyance direction (the left - right direction in FIG. 3) and the Y direction orthogonal to the substrate conveyance direction (the up - down direction in FIG. 3) are shown. In FIG. 4, the Z direction (the up - down direction in FIG. 4) is shown as the height direction orthogonal to the horizontal plane. The Z direction is the up - down direction or the orthogonal direction when the component mounting device is installed on the horizontal plane.

[0013] First, referring to FIG. 1, the configuration of the component mounting system 1 will be described. The component mounting system 1 is configured to connect three component mounting lines L1 to L3 arranged on the floor F by a communication network 2 and be 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. Each of the component mounting lines L1 to L3 is configured by connecting a plurality of production facilities including a screen printing device and a component mounting device as described later, and has a function of producing a mounted substrate (product) with components mounted on a substrate. Note that the number of component mounting lines L1 to L3 included in the component mounting system 1 does not have to be three, and may be one, two, or four or more.

[0014] In a preparation area As different from the production area Ap provided on the floor F, an arrangement work support device 4 is arranged. The arrangement work support device 4 is connected to the management computer 3 via the communication network 2. An exchangeable cart 5, which is the object of the arrangement work described later, is connected to the arrangement work support device 4. In the preparation area As, a plurality of carts 5 in various states, such as before, during, or after the execution of the arrangement work, are stored. Also, in the preparation area As, detachable elements such as a plurality of screen masks, tape feeders 9, mounting heads 12, suction nozzles 12b, and reels 17 (see FIG. 4), which are shared by the production facilities arranged on the floor F, are stored.

[0015] In FIG. 1, on the cart 5 connected to the placement work support device 4, placement work is performed in accordance with work instructions corresponding to the types of mounting substrates to be produced on the component mounting lines L1 to L3. As placement work, the operator performs work such as removing a plurality of tape feeders 9 and reels 17 that supply the instructed components from the cart 5, and attaching them to the instructed positions on the cart 5. On the cart 5 in the preparation area As including the cart 5 connected to the placement work support device 4, placement work can be executed in parallel with the production of the mounting substrates on the component mounting lines L1 to L3. Hereinafter, the preparation work for changing the component type outside the component mounting lines L1 to L3, including the placement work for the cart 5, is referred to as the outer setup work.

[0016] When changing the type of mounting substrate produced on the component mounting lines L1 to L3, the operator moves the cart 5 on which the placement work has been completed in the preparation area As to the component mounting lines L1 to L3, and executes a cart replacement work for replacing it with the cart 5 mounted on the component mounting device. Also, in the type change work, the operator moves and replaces the replacement screen mask, tape feeder 9, mounting head 12, suction nozzle 12b, reel 17, etc. stored in the preparation area As to the component mounting lines L1 to L3. Hereinafter, the preparation work for changing the component type within the component mounting lines L1 to L3 is referred to as the inner setup work.

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

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

[0019] The component mounting devices M3 to M6 perform a component mounting operation of mounting components on the substrate on which solder is deposited with the mounting head 12. Note that the component mounting line L1 is not limited to a configuration in which there are 4 component mounting devices M3 to M6, and the number of component mounting devices M3 to M6 may be 1 to 3 or 5 or more. The reflow device M7 performs a substrate heating operation of heating the substrate carried into the device by the substrate heating unit, curing the solder on the substrate, and joining the electrode portion of the substrate and the component. The substrate recovery device M8 includes a storage unit such as a rack for storing a plurality of substrates, and performs a substrate recovery operation of receiving the substrate carried out by the upstream device and recovering it in the storage unit.

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

[0021] A carriage 5, on which a plurality of tape feeders 9 are mounted in parallel in the X direction, is attached to the component supply section 8. The tape feeder 9 pitch-feeds a carrier tape, in which pockets for storing components D are formed, from the outside of the component supply section 8 in the direction (tape feed direction) toward the substrate transfer mechanism 7, thereby supplying the component D to the component pickup position where the mounting head 12 picks up the component D. That is, the tape feeder 9 is a component supply device that supplies the component D. In addition to the tape feeder 9, the component supply device may be a tray feeder that supplies the component D placed on a tray, a stick feeder that supplies the component D aligned and held on a hollow stick, or the like.

[0022] In FIG. 3, Y-axis tables 10 equipped with linear drive mechanisms are arranged at both ends in the X direction on the upper surface of the base 6. A beam 11, which is also equipped with a linear mechanism, is movably coupled to the Y-axis table 10 in the Y direction. A mounting head 12 is movably mounted on the beam 11 in the X direction. The mounting head 12 includes a plurality (here, eight) of nozzle units 12a. A plurality of types of mounting heads 12, which differ in the number of nozzle units 12a and the like, are prepared.

[0023] In FIG. 4, suction nozzles 12b for vacuum-sucking and holding the component D are mounted at the lower ends of the respective nozzle units 12a. A plurality of types of suction nozzles 12b, which differ in nozzle shape and the like, are prepared corresponding to the size and shape of the component D to be sucked.

[0024] In FIG. 3, the Y-axis table 10 and the beam 11 constitute a mounting head moving mechanism 13 that moves the mounting head 12 in the horizontal directions (X direction, Y direction). The mounting head moving mechanism 13 and the mounting head 12 suck and pick up the component D from the component pickup position of the tape feeder 9 attached to the component supply section 8 by the suction nozzle 12b. Then, the mounting head moving mechanism 13 transfers the mounting head 12 to the mounting position of the substrate B held by the substrate transfer mechanism 7 and executes a component mounting operation for mounting.

[0025] The time it takes for the mounting head 12 to pick up the component D from the tape feeder 9 and mount it on the substrate B depends on the position of the tape feeder 9 on the carriage 5 (the configuration of the component mounting apparatus). For example, by arranging the tape feeder 9 that supplies the component D with a large number of mounting points to be mounted on the substrate B near the center of the carriage 5, the moving distance of the mounting head 12 can be reduced and the mounting time can be shortened.

[0026] In FIGS. 3 and 4, a head camera 14 is mounted on the lower surface side of the beam 11 and moves integrally with the mounting head 12. As the mounting head 12 moves, the head camera 14 moves above the substrate B positioned at the mounting operation position of the substrate conveyance mechanism 7, and images a substrate mark (not shown) provided on the substrate B to recognize the position of the substrate B.

[0027] A component recognition camera 15 is installed between the component supply unit 8 and the substrate conveyance mechanism 7. When the mounting head 12 that has picked up the component D from the component supply unit 8 moves upward, the component recognition camera 15 images the component D held by the suction nozzle 12b to recognize the holding position and the like. In the component mounting operation of the component D on the substrate B by the mounting head 12, correction of the mounting position is performed in consideration of the recognition result of the substrate B by the head camera 14 and the recognition result of the component D by the component recognition camera 15.

[0028] In FIG. 4, a reel 17 around which a carrier tape 16 for storing the component D is wound is held on the front side of the carriage 5. The tape feeder 9 conveys the carrier tape 16 stored in the reel 17 in the tape feeding direction and supplies the component D to the component pickup position by the mounting head 12. The tape feeder 9 is prepared in a plurality of types with different widths and the like corresponding to the width of the carrier tape 16 to be conveyed.

[0029] As described above, the component mounting lines L1 to L3 are equipped with component mounting devices M3 to M6 that mount the components D supplied by the tape feeders 9 (component supply devices) onto the substrate B. Two carts 5, each having a plurality of tape feeders 9 (component supply devices) that supply components D of different component types, are mounted on each of the component mounting devices M3 to M6. That is, eight carts 5 are mounted on each of the component mounting lines L1 to L3 that include four component mounting devices M3 to M6. Hereinafter, the plurality of carts 5 mounted on the component mounting lines L1 to L3 for producing the mounting substrates are referred to as a "cart group".

[0030] Next, with reference to FIG. 5, the configuration of the management computer 3 will be described. The management computer 3 includes a processing unit 20, a production plan storage unit 21, a production data storage unit 22, a line information storage unit 23, and an actual result information storage unit 24, which are storage devices, as well as an input unit 25 and a display unit 26. The processing unit 20 is a data processing device such as a CPU, and includes an actual result information collection unit 27, an information acquisition unit 28, a range setting unit 29, a similarity rate calculation unit 30, a head plan creation unit 31, a facility configuration creation unit 32, a switching time calculation unit 33, a condition determination unit 34, a cycle time calculation unit 35, a group creation unit 36, a production plan update unit 37, a predicted time calculation unit 38, and a delay determination unit 39 as internal processing units.

[0031] The input unit 25 is an input device such as a keyboard, a touch panel, or a mouse, and is used when an operation command or data is input. The display unit 26 is a display device such as a liquid crystal panel, and displays various data stored in each storage unit, as well as various information such as an operation screen for the operation by the input unit 25 and a changeable range setting screen. Note that the management computer 3 does not necessarily have to be configured by a single computer, and may be configured by a plurality of devices. For example, all or part of the storage device may be provided in the cloud via a server.

[0032] In FIG. 5, the production plan storage unit 21 stores production plan information 21a, product type information 21b, cycle time information 21c, changeover time information 21d, etc. The production plan information 21a stores, for each lot number that identifies the lot of mounting substrates to be produced, information that identifies the product type of the mounting substrate, the production quantity, the startable date and time and production due date when production can be started, information that identifies the component mounting lines L1 to L3 for producing the mounting substrate, the planned start date and time and planned end date and time, the work schedule of the operator, and other production plans.

[0033] Here, with reference to FIG. 6, an example of the production plan information 21a will be described. The production plan information 21a includes a lot number 41, a product type number 42, a production quantity 43, a startable date and time 44, and a production due date 45. The lot number 41 is information that identifies the lot of mounting substrates produced on the component mounting lines L1 to L3. The product type number 42 is information that identifies the product type of the mounting substrate. The production quantity 43 is the production quantity of the mounting substrates in the lot. The startable date and time 44 is the date and time when production can be started because components such as component D are available on the floor F. The production due date 45 is the date and time by which the production of the mounting substrate must be completed. Hereinafter, the lot with the lot number 41 being "A" will be simply referred to as "lot A", the product type with the product type number 42 being "X1" will be simply referred to as "product type X1", etc.

[0034] In FIG. 5, the product type information 21b stores, for each product type number 42, information necessary for component mounting operations such as the component type of component D mounted on substrate B and the mounting position. The cycle time information 21c stores, for each lot number 41 (or product type number 42), the maximum value of the cycle time from when substrate B is loaded into the production equipment provided on the component mounting lines L1 to L3 until the production operation is executed and then unloaded. The changeover time information 21d stores the external setup operation time for changing the product type to be produced, the cart replacement time, and the internal setup operation time, in association with the combination of the product types before and after the changeover.

[0035] In FIG. 5, production data storage unit 22 stores production data information 22a and the like. In the production data information 22a, for each type (or lot) assigned to component mounting lines L1 to L3, information regarding the configuration of production facilities such as the arrangement positions of tape feeders 9 and reels 17 on carts 5, the mounting heads 12 mounted on component mounting devices M3 to M6, and the positions and types of suction nozzles 12b is stored. Also, in the production data information 22a, when the types (or lots) assigned to component mounting lines L1 to L3 are grouped, information on the types (or lots) belonging to the same group and information such as the arrangement positions of tape feeders 9 and reels 17 commonly arranged on a plurality of carts 5 (cart group) are also included.

[0036] Line information storage unit 23 stores line configuration information 23a, standard operation time information 23b, and the like. In the line configuration information 23a, information regarding the configuration of component mounting lines L1 to L3, such as the types of production facilities constituting component mounting lines L1 to L3 and the connected order, is stored. In the standard operation time information 23b, information regarding the standard operation time required for production, such as the standard required time for production work for each production facility constituting component mounting lines L1 to L3, is stored. For example, in the standard operation time information 23b, the loading time and unloading time of substrate B for each production facility, the printing time per substrate for screen printing device M2, and the mounting time per component for component mounting devices M3 to M6 are stored.

[0037] In FIG. 5, performance information storage unit 24 stores production performance information 24a, equipment configuration information 24b, and the like. In the production performance information 24a, for each lot number 41 of the mounting substrates produced or being produced on component mounting lines L1 to L3, the production start date and time, production end date and time, production performance number of sheets, and the like are stored. In the equipment configuration information 24b, the configuration of the production facilities of component mounting lines L1 to L3 during the production of the mounting substrates is stored for each lot number 41 (or product type number 42).

[0038] The management computer 3 of the present embodiment creates a "production plan for next week" as a production plan. Here, referring to FIG. 7, the production plan for next week created by the management computer 3 will be described. At the "current time" in the figure, the mounting substrate with lot number 41 included in the planned production product types 46a among the production plan information 21a shown in FIG. 6 is being produced. That is, lot P is being produced on the component mounting line L1, lot Q is being produced on the component mounting line L2, and lot R is being produced on the component mounting line L3. The production plan for next week is the production plan for the mounting substrates to be produced after the "start time of the shift for next week" in the figure.

[0039] That is, the production plan for next week is a production plan for producing the mounting substrates after lot A included in the planned production product types 46b among the production plan information 21a shown in FIG. 6. Note that the production plan created by the management computer 3 is not limited to the production plan for next week, and the management computer 3 creates the next production plan following the created production plan. For example, if the production plan until today has been created, the production plan from tomorrow following the production plan until today is created. Hereinafter, the next production plan created by the management computer 3 following the created production plan, including the production plan for next week, is simply referred to as the "next production plan".

[0040] In FIG. 5, the actual result information collection unit 27 sequentially collects information such as production results from each production facility of the component mounting lines L1 to L3, and stores it in the actual result information storage unit 24 as production result information 24a and equipment configuration information 24b. That is, in the equipment configuration information 24b, at least the current configuration of the component mounting devices M3 to M6 provided in the plurality of component mounting lines L1 to L3 is stored.

[0041] When creating the next production plan, the information acquisition unit 28 acquires the necessary information. Specifically, the information acquisition unit 28 collects from the production plan information 21a the lot number 41, part number 42, number of production pieces 43, available start date and time 44, and production due date 45 of the production item types (production item types 46b to be planned) to be produced from now on, and collects from the part type information 21b the part types of the parts D mounted on the substrate B of the production item types 46b to be planned. In addition, the information acquisition unit 28 collects from the production result information 24a the information on the production item types currently being produced on the component mounting lines L1 to L3, and collects from the equipment configuration information 24b the information on the current configurations of the component mounting devices M3 to M6.

[0042] In addition, when creating the next production plan, if the production of the last lot of the created production plan has not yet started, the information acquisition unit 28 acquires from the production data information 22a the information on the configurations of the component mounting devices M3 to M6 planned for the production of the last lot instead of the information on the current configurations of the component mounting devices M3 to M6. That is, the "current configurations of the component mounting devices M3 to M6" acquired by the information acquisition unit 28 are the "configurations of the component mounting devices M3 to M6 when producing the last lot planned in the created production plan".

[0043] In FIG. 5, when the range setting unit 29 switches the configuration of the component mounting devices M3 to M6 from the configuration (current configuration) in which the last lot of the created production plan is produced to the configuration in which the first lot of the next production plan is produced, the range setting unit 29 sets the changeable range. Specifically, the range setting unit 29 causes the display unit 26 to display a changeable range setting screen, and sets the changeable range based on the information input by the administrator operating the input unit 25.

[0044] Here, with reference to FIG. 8, an example of the changeable range setting screen 47 displayed by the range setting unit 29 on the display unit 26 will be described. On the changeable range setting screen 47, a "condition setting" area 48, a "producerable item type setting" area 49, a "cancel" button 50, and a "set" button 51 are displayed. In the "condition setting" area 48, input fields 48a for inputting "similarity rate", "number of replacement feeders", "number of workers", and "working time" are displayed.

[0045] The similarity rate is the ratio of similarity between the planned production product type 46b and the mounting substrates that can be produced with the current configurations of the component mounting apparatuses M3 to M6. Specifically, the similarity rate calculation unit 30 calculates, as the similarity rate, the ratio of the commonality between the component types that can be mounted on the substrate B with the current configurations of the component mounting apparatuses M3 to M6 and the component types required for the production of the planned production product type 46b. In the example of FIG. 8, "90% or more" is set as the similarity rate. This means that, in producing the planned production product type 46b, the range of component types that can be changed from the current configurations of the component mounting apparatuses M3 to M6 is less than "10%" of the whole.

[0046] Here, referring to FIG. 9, an example of the similarity rate 52 calculated by the similarity rate calculation unit 30 will be described. FIG. 9 shows the similarity rate 52 calculated with product types X1 to X8 in FIG. 6 as the planned production product type 46b with respect to the current configuration in which the lot P (product type Y7) is being produced on the component mounting line L1 (line L1) shown in FIG. 7, the lot Q (product type Y8) is being produced on the component mounting line L2 (line L2), and the lot R (product type Y9) is being produced on the component mounting line L3 (line L3). That is, for each product number 42, the similarity rate 52a when producing on line L1, the similarity rate 52b when producing on line L2, and the similarity rate 52c when producing on line L3 are displayed.

[0047] In FIG. 8, the number of exchange feeders is the upper limit of the number of tape feeders 9 (component supply apparatuses) that can be exchanged from the current component mounting apparatuses M3 to M6. The number of workers is the upper limit of the number of people that can be assigned as the workers who perform the work for product type change. The working time is the upper limit of the working time that is allowed as the work for product type change.

[0048] In the "Set producible product types" area 49, among the planned production product types 46a, the product types to be left as producible product types (producible product types) in the future are set. The management computer 3 creates a production plan for the planned production product types 46b within the range where the producible product types are producible. The administrator uses the input unit 25 to slide the scroll bar 49a and operates the selection button 49b (to make it in the state of a black square in the figure) to set the producible product types.

[0049] In Fig. 8, when the "Cancel" button 50 is operated, the screen transitions from the changeable range setting screen 47 to the previous screen. When the "Set" button 51 is operated, the range setting unit 29 sets the changeable range based on the conditions set in the "Condition setting" area 48 and the "Set producible product types" area 49 from the current configuration. For example, the range setting unit 29 sets the most restrictive condition among the conditions in the "Condition setting" area 48 and the "Set producible product types" area 49 as the changeable range. Note that the range setting unit 29 may be set to set any one of the conditions as the changeable range.

[0050] In this way, the range setting unit 29 sets the changeable range based on at least any one of the number of component supply devices (tape feeders 9) arranged in the component mounting devices M3 to M6 (the number of replaceable feeders), the number of workers (number of workers) who change the configuration of the component mounting devices M3 to M6, the time (working time) to change the configuration of the component mounting devices M3 to M6, and the producible product types (producible product types) producible on the component mounting lines L1 to L3.

[0051] In Fig. 5, the leading plan creation unit 31 creates a leading plan that assigns the planned production product types 46b (hereinafter referred to as "leading production product types") to be produced first on the component mounting lines L1 to L3 in the next production plan based on the similarity rate 52. Specifically, the planned production product types 46b are assigned to the plurality of component mounting lines L1 to L3 in descending order of the similarity rate 52.

[0052] In the example of FIG. 9, first, the leading plan generation unit 31 assigns the lot E of product variety X5 with the highest similarity rate 52 of "94%" to the component mounting line L1. Next, the leading plan generation unit 31 assigns the lot B of product variety X2 with the second highest similarity rate 52 of "92%" to the component mounting line L2. Next, the lot E of product variety X5 with a similarity rate 52 of "92%" is the next highest, but the lot E has already been assigned to the component mounting line L1. Therefore, the leading plan generation unit 31 assigns the lot F of product variety X6 with a similarity rate 52 of "91%" and the next highest to the component mounting line L3.

[0053] In FIG. 5, when the leading plan generation unit 31 satisfies the conditions within the changeable range set by the range setting unit 29, it creates a leading plan in which the leading production product variety is assigned to the component mounting lines L1 to L3 and stores it in the production plan information 21a. When the leading plan generation unit 31 does not satisfy the changeable conditions, it causes the display unit 26 to display a warning indicating that assignment is impossible, prompting the administrator to take measures such as relaxing the changeable range. In the example of FIG. 9, when the changeable range is "similarity rate of 90% or more", the leading production product variety can be assigned to all the component mounting lines L1 to L3. When the changeable range is "similarity rate of 92% or more", since there is no leading production product variety that can be assigned to the component mounting line L3, the leading plan generation unit 31 causes the display unit 26 to display a warning to that effect.

[0054] In this way, when producing the planned production product variety 46b (the production product variety to be produced), the leading plan generation unit 31 is a production plan generation unit that creates a production plan in which the planned production product variety 46b is assigned to a plurality of component mounting lines L1 to L3 based on the similarity rate 52 under the condition that the configuration of the component mounting devices M3 to M6 is changed within a predetermined changeable range from the current configuration. In addition, if the truck replacement operation of the spare truck group is also within the predetermined changeable range, the leading plan generation unit 31 may create a leading plan including the truck replacement operation. In that case, the similarity rate calculation unit 30 calculates the similarity rate 52 with the virtual component mounting devices M3 to M6 equipped with the spare truck group.

[0055] In FIG. 5, the equipment configuration creation unit 32 determines the configuration of each production facility including the component mounting devices M3 to M6 for each lot based on the assigned component mounting lines L1 to L3, groups, production order information, product type information 21b, and equipment configuration information 24b included in the production plan information 21a, and stores it in the production data information 22a. When the lots are grouped, the equipment configuration creation unit 32 determines the configuration of the production equipment so that the tape feeder 9 and the reel 17 are commonly arranged on the carriage 5 so that the lots belonging to the group can be produced without replacing the carriage 5.

[0056] The changeover time calculation unit 33 calculates (predicts) the changeover time for changing the configuration of the component mounting devices M3 to M6 for the next production product type in each of the component mounting lines L1 to L3 based on the number of workers set by the range setting unit 29 and the production data information 22a. The changeover time includes the internal setup time for replacing the tape feeder 9 and the reel 17 of the carriage 5 mounted on the component mounting devices M3 to M6 when switching to a product type within the group. When switching to a product type outside the group, the carriage replacement work time for replacing the carriage 5 (carriage group) prepared by the external setup work with the carriage 5 mounted on the component mounting devices M3 to M6 is further included.

[0057] The changeover time calculation unit 33 stores the calculated changeover time in the production plan storage unit 21 as the changeover time information 21d. In the production plan (head plan) shown in FIG. 10(a), the predicted internal setup time required to configure the component mounting devices M3 to M6 to produce the lots E, B, and F is indicated by diagonal hatching.

[0058] In FIG. 5, the condition determination unit 34 determines whether the configurations of the component mounting devices M3 to M6 determined by the equipment configuration creation unit 32 and the internal setup operation time calculated by the switching time calculation unit 33 satisfy the changeable range set by the range setting unit 29. When the calculated internal setup operation time exceeds the set operation time, the condition determination unit 34 determines that the set changeable range is not satisfied. Further, when the number of component supply devices (tape feeders 9) to be replaced to configure the determined component mounting devices M3 to M6 exceeds the set number of replaceable feeders, the condition determination unit 34 determines that the set changeable range is not satisfied.

[0059] The cycle time calculation unit 35 calculates the cycle time per mounting substrate for producing the production product type 46b to be planned based on the configuration of the production equipment included in the production data information 22a and the standard operation time information 23b, and stores it in the cycle time information 21c. Further, the cycle time calculation unit 35 multiplies the calculated cycle time by the number of production substrates 43 to calculate the production time required to produce the production product type 46b to be planned. In the production plan (initial plan) shown in FIG. 10(a), the production times of lots E, B, and F on the component mounting lines L1 to L3 are respectively displayed as rectangles. The length of the rectangle along the production time is the production time.

[0060] In FIG. 5, the group creation unit 36 calculates the commonality of components among the plurality of production product types 46b to be planned based on the product type information 21b of the production product type 46b (the production product type to be produced), and groups them as a group in which the tape feeders 9 and reels 17 for the plurality of product types are commonly arranged on the cart 5 (cart group) based on the calculated commonality. In FIG. 10(b), among the production product types 46b to be planned, the product type X5 (lot E), the product type X3 (lot C), and the product type X4 (lot D) have a high commonality and are grouped as a group. Similarly, the product type X7 (lot G) and the product type X8 (lot H) also have a high commonality and are grouped as a group.

[0061] In FIG. 5, based on the production plan information 21a, the production plan update unit 37 assigns the production product types 46b other than the leading production product type to the component mounting lines L1 to L3 for the leading plan to which the leading production product type is assigned. The production plan update unit 37 updates (creates) the production plan so that the production product types 46b in the same group are continuously produced. Alternatively, the production plan update unit 37 changes the production order of the assigned production product types 46b. The created production plan is stored in the production plan storage unit 21 as the production plan information 21a.

[0062] Based on the production plan created by the production plan update unit 37, the switching time (cart replacement operation time, internal setup operation time) calculated by the switching time calculation unit 33, and the production time calculated by the cycle time calculation unit 35, the predicted time calculation unit 38 calculates the predicted production completion time of the target production product type. That is, the predicted time calculation unit 38 calculates the predicted production completion time of the target production product type including the switching time based on the production quantity (production number 43) of the production product types 46b to be produced (planned production product types) and the created production plan.

[0063] In FIG. 5, based on the predicted production completion time calculated by the predicted time calculation unit 38 and the production delivery date 45 included in the production plan information 21a, the delay determination unit 39 determines whether there is a product type (lot) for which the expected production end time is later than the production delivery date 45. That is, the delay determination unit 39 determines whether the predicted production completion time delays the production delivery date 45 of the production product types 46b to be planned.

[0064] When it is determined by the delay determination unit 39 that there is a delay, the production plan update unit 37 changes the assignment of the production product types 46b to be planned in the production plan to the component mounting lines L1 to L3 or changes the production order of the production product types 46b to be planned. By repeating the delay determination and the production plan change, a production plan (production plan information 21a) that satisfies the production delivery date 45 and production data (production data information 22a) are created simultaneously.

[0065] Referring to FIG. 10(b) here, an example of the production plan created by the production plan update unit 37 will be described. On the component mounting line L1, following the first production product type, product type X5 (lot E), the production of lot C (product type X3) and lot D (product type X4) in the same group as lot E is assigned. The switch from lot E to lot C and the switch from lot C to lot D are only in-line changeover operations without the replacement of the carriage 5. On the component mounting line L2, following the first production product type, product type X2 (lot B), the production of lot A (product type X1) which is not in the same group as lot B is assigned. The switch from lot B to lot A is performed by a carriage replacement operation of replacing the carriage 5 (carriage group) prepared in advance in the off-line changeover operation with the carriage 5 mounted on the component mounting devices M3 to M6.

[0066] On the component mounting line L3, following the first production product type, product type X6 (lot F), lot G (product type X7) and lot H (product type X8) which do not belong to the group to which lot F belongs are assigned. The switch from lot F which is not in the same group to lot G is a carriage replacement operation, and the switch from lot G in the same group to lot H is only an in-line changeover operation.

[0067] As described above, the management computer 3 including the similarity rate calculation unit 30 and the production plan creation unit (the first plan creation unit 31) is a production plan creation system that creates a production plan for producing mounting substrates of a plurality of product types by a plurality of component mounting lines L1 to L3 including the component mounting devices M3 to M6. Thereby, the next production plan can be automatically created from the current situations of the component mounting lines L1 to L3.

[0068] Next, a production plan creation method (production plan creation program) for creating a production plan to produce mounting substrates of a plurality of product types by component mounting lines L1 to L3 using a management computer 3 (production plan creation system) will be described along the flow of FIG. 11. In FIG. 11, first, a leading plan creation unit 31 creates a leading plan in which leading production product types are assigned to component mounting lines L1 to L3 (ST1: leading plan creation step). Next, a group creation unit 36 calculates the commonality of production product types 46b to be planned and creates groups (ST2: group creation step).

[0069] Next, when a group is created, a production plan update unit 37 creates a production plan in which production product types 46b to be planned excluding the leading production product type are assigned to the leading plan so that a group is formed (ST3: production plan update step). Next, an equipment configuration creation unit 32 creates the configuration of component mounting devices M3 to M6 when producing each production product type 46b to be planned based on the order of the created production plan (ST4: first equipment configuration creation step). Next, a switching time calculation unit 33 calculates the switching time for changing the configuration of component mounting devices M3 to M6 for the next production product type on component mounting lines L1 to L3 (ST5: first switching time calculation step).

[0070] In FIG. 11, next, a cycle time calculation unit 35 calculates the cycle time for producing production product types 46b to be planned on component mounting lines L1 to L3, respectively (ST6: first cycle time calculation step). Next, a predicted time calculation unit 38 calculates the predicted production completion time of production product types 46b to be planned including the switching time based on the created production plan (ST7: production completion predicted time calculation step). Next, a delay determination unit 39 determines whether or not the calculated predicted production completion time has delayed the production delivery date 45 for all production product types 46b to be planned (ST8: delay determination step).

[0071] When there is a production product type 46b for which the predicted production completion time delays the production delivery date 45 (Yes in ST8), the process returns to the group creation process (ST2), and the production plan update process (ST3) is executed. That is, when the predicted production completion time delays the production delivery date 45, in the production plan update process (ST3), the allocation of the production product type 46b in the production plan to the component mounting lines L1 - L3 or the production order of the production product type 46b is changed. That is, the allocation of the leading production product type (leading plan) is not changed, and the allocation of the production product type 46b other than the leading production product type to the component mounting lines L1 - L3 and the production order are changed.

[0072] In FIG. 11, when all production product types 46b (production product types to be produced hereafter) satisfy the production delivery date 45 in the delay determination process (ST8) (No in ST8), the production plan is stored in the production plan information 21a (ST9: production plan storage process), and the production plan creation is completed.

[0073] Next, the details of the leading plan creation process (ST1) will be described along the flow of FIG. 12. In the leading plan creation process (ST1), first, the information acquisition unit 28 acquires the configuration of the production facilities of the component mounting lines L1 - L3 included in the line configuration information 23a (ST11: line configuration information acquisition process). Next, the information acquisition unit 28 acquires the current configuration of the component mounting devices M3 - M6 provided in the plurality of component mounting lines L1 - L3 included in the equipment configuration information 24b (ST12: current equipment configuration information acquisition process).

[0074] Next, the information acquisition unit 28 acquires the information of the production product types (production product types 46b to be produced hereafter) included in the production plan information 21a and the product type information 21b (ST13: product type information acquisition process). In the product type information acquisition process (ST13), information regarding the production quantity (production number of sheets 43) and the production delivery date 45 of the production product type 46b is also acquired. Next, the range setting unit 29 causes the display unit 26 to display the changeable range setting screen 47 (see FIG. 8), and sets the range in which the configuration of the component mounting devices M3 - M6 can be changed from the current configuration when producing the production product type 46b (ST14: changeable range setting process).

[0075] In FIG. 12, next, the similarity rate calculation unit 30 calculates the similarity rate 52 of the production product type 46b to be planned and the mounting substrates producible in the current configurations of the component mounting apparatuses M3 to M6 (ST15: similarity rate calculation step). Next, the leading plan creation unit 31 creates a leading plan (production plan) in which the production product types 46b to be planned are assigned to the plurality of component mounting lines L1 to L3 in descending order of the similarity rate 52 (ST16: leading lot allocation step). When the lower limit of the similarity rate 52 is set as the changeable range in the changeable range setting step (ST14), and when it is not possible to assign all the production product types 46b that satisfy the similarity rate 52 as the leading production product types to all the component mounting lines L1 to L3 (No in ST17), the process returns to the changeable range setting step (ST14) to review the changeable range.

[0076] When the leading production product types are assigned to all the component mounting lines L1 to L3 (Yes in ST17), next, the equipment configuration creation unit 32 creates the configurations of the component mounting apparatuses M3 to M6 for producing the leading production product types on the component mounting lines L1 to L3 (ST18: second equipment configuration creation step). Next, the switching time calculation unit 33 calculates the switching time for changing the configurations of the component mounting apparatuses M3 to M6 from the current configurations to those for the leading production product types (ST19: second switching time calculation step). Next, the condition determination unit 34 determines whether or not the switching to the configurations for the leading production product types satisfies the changeable range (number of replacement feeders, working time, etc.) (ST20: condition determination step).

[0077] In FIG. 12, when the changeable range is not satisfied (No in ST20), the process returns to the changeable range setting step (ST14) to review the changeable range. When the changeable range is satisfied (Yes in ST20), the cycle time calculation unit 35 calculates the cycle time of the first production product type (ST21). Next, the first plan is stored in the production plan information 21a (ST22: first plan storage step). As a result, when starting the next production plan from the created production plan, a production plan that can start the production of the first production product type (first production product type) earlier by changing the configuration of the component mounting lines L1 to L3 in the changeable range switching operation can be automatically created.

[0078] As described above, the production plan creation method of the present embodiment acquires the current configuration (equipment configuration information 24b) of the component mounting devices M3 to M6 provided in the component mounting lines L1 to L3 (ST12), and acquires information on the production product types 46b to be planned (production product types to be produced in the future) (ST13). Then, the similarity rate 52 of the mounting substrates that can be produced in the current configuration of the production product types 46b to be planned and the component mounting devices M3 to M6 is calculated (ST15), and a production plan in which the production product types 46b to be planned are assigned to the plurality of component mounting lines L1 to L3 is created based on the similarity rate 52 (ST16). As a result, the next production plan can be automatically created from the current situation of the component mounting lines L1 to L3.

Industrial Applicability

[0079] The production plan creation method, production plan creation system, and production plan creation program of the present invention have the effect of being able to create the next production plan from the current situation of the component mounting line, and are useful in the field of mounting components on a substrate.

Explanation of Reference Numerals

[0080] 3 Management computer (production plan creation system) 9 Tape feeder (component supply device) 46b Production product types to be planned (production product types to be produced in the future) B Substrate D component Component mounting lines L1 - L3 Component mounting devices M3 - M6

Claims

1. A production plan creation method for creating a production plan for producing mounting substrates of a plurality of production product types by a component mounting line including a component mounting device that mounts components supplied by a component supply device onto a substrate, wherein the production plan assigns a plurality of production product types to a plurality of component mounting lines, a step of obtaining the current configuration of the component mounting devices provided in the plurality of component mounting lines, a step of obtaining information on the production product types to be produced hereafter, a step of calculating a similarity rate between the production product types to be produced hereafter and the production product types producible in the current configuration of the component mounting device, and a step of creating a production plan in which the production product types to be produced hereafter are assigned to any one of the plurality of component mounting lines based on the similarity rate. A production plan creation method.

2. In the step of creating the production plan, the production product type is assigned to the component mounting line on the condition that the configuration of the component mounting device is changed within a predetermined changeable range from the current configuration when producing the production product type. The production plan creation method according to claim 1.

3. The production plan creation method according to claim 2, further including a step of setting the changeable range based on the number of the component supply devices arranged in the component mounting device.

4. The production plan creation method according to claim 2, further including a step of setting the changeable range based on the number of workers who change the configuration of the component mounting device.

5. The production plan creation method according to claim 2, further including a step of setting the changeable range based on the time for changing the configuration of the component mounting device.

6. The production plan creation method according to claim 2, further including a step of setting the changeable range based on the production product types producible in the component mounting line.

7. A step of calculating a predicted production completion time of the production product type based on the created production plan, and a step of changing the production order of the production product type when the predicted production completion time delays the production delivery date. The production plan creation method according to any one of claims 1 to 6.

8. The production plan creation method according to claim 7, further including a step of changing the assignment of the production product type to the component mounting line when the predicted production completion time delays the production delivery date.

9. The method for creating a production plan according to claim 7 or 8 further includes a step of calculating a switching time for changing the configuration of the component mounting device to that for the next production product type in the component mounting line. The predicted completion time of production of the production product type is calculated including the switching time, the production plan creation method according to claim 7 or 8.

10. A production plan creation system for creating a production plan for mounting substrates of a plurality of production product types by a plurality of component mounting lines each including a component mounting device for mounting components supplied by a component supply device on a substrate, a similarity rate calculation unit that calculates a similarity rate between the production product type to be produced and the production product types that can be produced in the current configuration of the component mounting device based on the current configuration of the component mounting device included in the component mounting line and information on the production product type to be produced hereafter; a production plan creation unit that creates a production plan in which the production product type to be produced hereafter is assigned to any one of the plurality of component mounting lines based on the similarity rate.

11. A production plan creation program for causing a computer to execute creation of a production plan for mounting substrates of a plurality of production product types by a plurality of component mounting lines each including a component mounting device for mounting components supplied by a component supply device on a substrate, the step of obtaining the current configuration of the component mounting device included in the component mounting line; the step of obtaining information on the production product type to be produced hereafter; the step of calculating a similarity rate between the production product type to be produced hereafter and the production product types that can be produced in the current configuration of the component mounting device; and the step of creating a production plan in which the production product type to be produced hereafter is assigned to any one of the plurality of component mounting lines based on the similarity rate.

Images