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 component mounting lines with different configurations, a production capacity estimation method, and a production capacity estimation program.SOLUTION: The production capacity estimation method for estimating the production capacity of producing mounting boards in a component mounting line includes the steps of: estimating the production capacity of 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, production data for a component mounting unit, a piece of worker information about workers, a piece of line information about the configuration of the component mounting line, a piece of specification information on the specifications of the component mounting unit, and a piece of event: information on events that require worker action and their frequency (ST5); and comparing multiple estimated production capacities and displaying the same on a display unit (ST6).SELECTED DRAWING: Figure 9

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 composed of multiple component mounting devices, including a component mounting device, mounted boards with components mounted on them are continuously produced. In order to estimate the production capacity of such a component mounting line, it is necessary to take into account not only the processing capacity of each component mounting device, but also temporary suspension of the component mounting device due to worker tasks such as supplying components and other materials to the component mounting device or responding to errors in the component mounting device (see, for example, Patent Document 1). The system described in Patent Document 1 discloses that it 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 about the component mounting devices, and the frequency of worker tasks, as well as input information about the workers and a production plan. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2017-199742 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 with a given configuration to produce mounted boards, they cannot estimate the extent to which the component mounting line is actually utilizing its ideal production capacity, and there is room for further improvement in comprehensively estimating 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 production capacities of 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 the production capacity of a component mounting line made up of a plurality of component mounting devices to produce mounted boards, and includes: a production capacity estimation unit that estimates the production capacity of the component mounting line based on a production plan for the mounted boards to be produced in the component mounting line, board information related to the configuration of the mounted boards, production data for the component mounting devices to execute production work for the mounted boards, worker information related to workers who work on the component mounting devices, line information related to the configuration of the component mounting line, specification information related to the specifications of the component mounting devices, and event information related to events that require work by workers on the component mounting line and their occurrence frequency; and a display unit that compares and displays the estimated production capacities. The production capacity estimation unit estimates at least two of an ideal production capacity estimated based on the specifications of the component mounting device, an event-free production capacity estimated on the assumption that the event will not occur, and an event-occurrence production capacity estimated in consideration of the frequency of occurrence of the event. . and event information relating to events that require worker work on the component mounting line and their frequency of occurrence; a production capacity estimation system for estimating the production capacity of a component mounting line made up of a plurality of component mounting devices, the production capacity estimation system including: a production capacity estimation unit that estimates the production capacity of the component mounting line based on a production plan for the mounting boards to be produced on the component mounting line, board information relating to the configuration of the mounting boards, production data for the component mounting devices to execute production work of the mounting boards, worker information relating to workers who work on the component mounting devices, line information relating to the configuration of the component mounting line, specification information relating to the specifications of the component mounting devices, and event information relating to events that require worker work on the component mounting line and their frequency of occurrence; a display unit that compares and displays the plurality of estimated production capacities; a performance collection unit that collects operation performance data of the plurality of component mounting devices; and a production capacity calculation unit that calculates an actual production capacity, which is an actual value of the production capacity, from the operation performance data; and the display unit compares and displays the estimated production capacity with the actual production capacity.

[0007] The production capacity estimation method of the present invention is a production capacity estimation method for estimating the production capacity of a component mounting line made up of a plurality of component mounting devices to produce mounted boards, and includes a production capacity estimation step of estimating the production capacity of the component mounting line based on a production plan for mounted boards to be produced in the component mounting line, board information relating to the configuration of the mounted boards, production data for the component mounting devices to execute production work on the mounted boards, worker information relating to workers who work on the component mounting devices, line information relating to the configuration of the component mounting line, specification information relating to the specifications of the component mounting devices, and event information relating to events that require work by workers on the component mounting line and their occurrence frequency, and a display step of comparing the plurality of estimated production capacities and displaying the results on a display unit. The production capacity estimation step estimates at least two of an ideal production capacity estimated based on the specifications of the component mounting device, a non-event production capacity estimated on the assumption that the event will not occur, and an event production capacity estimated in consideration of the frequency of occurrence of the event. . and a display step of comparing the estimated production capacities and displaying the results on a display unit. The production capacity estimation method of the present invention is a production capacity estimation method for estimating the production capacity of a component mounting line made up of a plurality of component mounting devices to produce mounted boards, the production capacity estimation method comprising: a production capacity estimation step of estimating the production capacity of the component mounting line based on a production plan for the mounted boards to be produced in the component mounting line, board information relating to the configuration of the mounted boards, production data for the component mounting devices to perform production work on the mounted boards, worker information relating to workers who work on the component mounting devices, line information relating to the configuration of the component mounting line, specification information relating to the specifications of the component mounting devices, and event information relating to events that require worker work on the component mounting line and their frequency of occurrence; and a display step of comparing the estimated production capacities and displaying the results on a display unit. The production capacity estimation method further comprises a performance collection step of collecting operation performance data of the plurality of component mounting devices, and a production capacity calculation step of calculating an actual production capacity, which is an actual value of the production capacity, from the operation performance data. The display step compares and displays the estimated production capacity with the actual production capacity.

[0008] The production capacity estimation program of the present invention is a production capacity estimation program that causes a computer to estimate a production capacity for producing mounted boards by a component mounting line made up of a plurality of component mounting devices, and includes a production capacity estimation step of estimating the production capacity of the component mounting line based on a production plan for the mounted boards to be produced in the component mounting line, board information related to the configuration of the mounted boards, production data for the component mounting devices to perform production work on the mounted boards, worker information related to workers who work on the component mounting devices, line information related to the configuration of the component mounting line, specification information related to the specifications of the component mounting devices, and event information related to events that require work by workers on the component mounting line and their occurrence frequency, and a display step of comparing the plurality of estimated production capacities and displaying the results on a display unit. The production capacity estimation step estimates at least two of an ideal production capacity estimated based on the specifications of the component mounting device, an event-free production capacity estimated on the assumption that the event will not occur, and an event-occurrence production capacity estimated in consideration of the frequency of occurrence of the event. . and a display step of comparing the estimated production capacities and displaying the results on a display unit. The program further includes a performance collection step of collecting operation records of the component mounting devices and a production capacity calculation step of calculating an actual production capacity, which is an actual value of the production capacity, from the operation records. The display step compares the estimated production capacity with the actual production capacity. [Effects of the Invention]

[0009] According to the present invention, it is possible to easily compare the production capacities of component mounting lines with different configurations. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a diagram illustrating the configuration of a component mounting system according to an embodiment of the present invention. [Figure 2] FIG. 1 is a diagram illustrating the configuration of a component mounting line provided in a component mounting system according to an embodiment of the present invention. [Figure 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. 10 is an explanatory diagram of an example of a new floor setting screen displayed on a display unit provided in a management computer (production capacity estimation system) according to an embodiment of the present invention. [Figure 5] FIG. 10 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. [Figure 6] FIG. 10 is an explanatory diagram of an example of a simulation result (current floor performance) display screen displayed by a display unit of a management computer (production capacity estimation system) according to an embodiment of the present invention; [Figure 7] FIG. 10 is an explanatory diagram of an example of a simulation result (current floor estimation) 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] FIG. 10 is an explanatory diagram of an example of a simulation result (new floor estimation) display screen displayed on a display unit of a management computer (production capacity estimation system) according to an embodiment of the present invention; [Figure 9] 1 is a flow diagram of a production capacity estimation method according to an embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0011] An embodiment of the present invention will be described in detail below with reference to the drawings. The configurations, shapes, etc. described below are examples for the purpose of explanation and can be modified as appropriate depending on the specifications of the component mounting system, component mounting line, management computer (production capacity estimation system), component mounting device, etc. In the following, corresponding elements in all drawings will be given the same reference numerals, and duplicated explanations will be 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 a 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 component mounting system 1 will be described with reference to Fig. 1. Component mounting system 1 is configured such that three component mounting lines L1 to L3 arranged on floor F are connected via a communication network 2 and managed by a management computer 3. Each component mounting line L1 to L3 is configured by connecting multiple component mounting devices, including a component mounting device, as will be described later, and has the function of producing mounted boards with components mounted on boards. Note that component mounting system 1 does not need to have three component mounting lines L1 to L3, and may have one, two, four or more.

[0013] Next, the detailed configuration of component mounting lines L1 to L3 will be described with reference to Figure 2. Component mounting lines L1 to L3 have the same configuration, and only component mounting line L1 will be described below. Component mounting line L1 is configured by connecting component mounting devices, such as solder printing device M1, print inspection device M2, component mounting devices M3 to M6, mounting inspection device M7, and reflow device M8, in series from upstream (left side of the page) to downstream (right side of the page) in the board transport direction. Note that component mounting line L1 is a group of component mounting devices connected via communication network 2, and the component mounting devices do not necessarily have to be physically connected to each other.

[0014] Solder printing device M1, print inspection device M2, component mounting devices M3 to M6, mounting inspection device M7, and reflow device M8 are connected to management computer 3 via communication network 2. Solder printing device M1 performs solder printing work by printing solder onto board B carried in from upstream by the solder printing work unit through a mask with multiple openings formed in it. In the setup work of switching the mounted board to be produced, worker W performs work such as changing the mask and changing the arrangement of support pins that support board B from below during solder printing.

[0015] 2, print inspection device M2 performs print inspection work by inspecting the condition of solder printed on board B using a print inspection work unit including a solder inspection camera. Note that a solder application device that applies solder to board B 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.

[0016] In Fig. 2, component mounting devices M3 to M6 perform component mounting work by mounting components D onto a board B using a component mounting work unit including a conveyor, a component supply unit, 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 include one to three, or five or more component mounting devices M3 to M6. In component mounting devices M3 to M6, a conveyor extending in the board transport direction transports the board B to a component mounting position. The component supply units are located outside the conveyor (front and rear).

[0017] The component supply unit is equipped with a cart carrying multiple tape feeders that feed the carrier tape holding the components D by tape feeding, and a tray feeder that supplies the components D while switching between trays holding multiple components D, and supplies the components D to a pickup position by the mounting head. The mounting head is equipped with multiple suction nozzles that vacuum-suck the components D, and performs component mounting work by picking up the components D supplied by the component supply unit and transferring and mounting them onto board B, which is transported, positioned, and held by a conveyor. During setup changeover, the tape feeders and trays in the component supply unit are set with carrier tapes and trays that hold the specified components D so that the specified components D are supplied according to the type of board to be mounted (in other words, the components D are arranged).

[0018] 2, in component mounting devices M3 to M6, when the components D held by the component supply unit are consumed and fall below a predetermined remaining number while component mounting work continues repeatedly (when a component out-of-component warning occurs), or when the components D run out (when a component out-of-component occurs), a worker W performs a component D replenishment operation (replenishing carrier tape, replacing trays, etc.). Also, when an apparatus error occurs that stops component mounting devices M3 to M6, such as a suction error where the suction nozzle does not properly suction components D, or an error where the tape feeder stops supplying components D because the carrier tape has become tangled (jammed), a recovery operation from the apparatus error is performed by worker W.

[0019] In addition, during the changeover work to switch the mounting boards to be produced, workers W perform tasks such as replacing tape feeders, replacing trays, replacing mounting heads, replacing suction nozzles, and changing the position of support pins that support board B from below during component mounting on component mounting devices M3 to M6.

[0020] 2, when performing the above-mentioned tasks, worker W moves to the operation surface (front or rear) of component mounting device M3-M6 that is the target of the task and performs the task. There are also device errors in which component mounting work on the front or rear where the device error occurred stops, while component mounting work continues on the opposite side without stopping, and device errors that are automatically recovered from by the recovery process of component mounting devices M3-M6. Thus, component mounting devices M3-M6 have equipment elements such as tape feeders, tray feeders, mounting heads, and suction nozzles, and perform component mounting work to produce mounted boards.

[0021] 2, mounting inspection device M7 performs mounting inspection work by inspecting the state of components D mounted on board B using a mounting inspection work section including a component inspection camera. Reflow device M8 performs board heating work by heating board B carried into the device using a board heating section to harden the solder on board B and bond the electrodes of board B to components D. Note that component mounting line L1 does not necessarily have to be equipped with mounting inspection device M7.

[0022] 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 provided in the management computer 3 (production capacity estimation system), the function of estimating the production capacity of component mounting lines L1 to L3 and comparing and displaying the production capacities will be described. The management computer 3 includes a processing unit 10, a storage unit 17 as a storage device, an input unit 28, a display unit 29, and a communication unit 30.

[0023] The processing unit 10 is a data processing device such as a CPU, and includes internal processing units such as a performance collection unit 11, a production capacity calculation unit 12, a display processing unit 13, a floor information creation unit 14, an optimization processing unit 15, a production capacity estimation unit 16, and a control unit (not shown). Each internal processing unit may be configured with independent hardware assets, or may be configured with a common CPU and programs 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 as a single computer, but may be configured as multiple devices. For example, the memory unit 17 and all or some of the data processing units that make up the management computer 3 may be provided in the cloud via a server.

[0024] 3, input unit 28 is an input device such as a keyboard, touch panel, or mouse, and is used to input operation commands and data. Display unit 29 is a display device such as a liquid crystal panel, and displays various data stored in memory unit 17, as well as various information such as an operation screen and input screen for operation by input unit 28. Communication unit 30 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 make up component mounting lines L1 to L3.

[0025] 3, storage unit 17 stores production plan information 18, board information 19, production data 20, worker information 21, floor information 22, specification information 23, event information 24, operation record 25, record production capacity information 26, estimated production capacity information 27, etc. Production plan information 18 stores a plurality of production plans, such as production plans with production records and new production plans, including the production order, planned production start time, planned production end time, etc. of mounted boards (board types) produced on component mounting lines L1 to L3 (or floor F). Board information 19 stores, for each board type of mounted board, information on the configuration of the mounted board, such as the size of board B, the mounting position of component D, and the type of component D.

[0026] The production data 20 stores, for each type of mounting board, information specifying the mask to be attached to the solder printing device M1, information on the placement of support pins, etc. The production data 20 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, information on the placement of support pins, information on the arrangement of components D in the component supply unit, etc. In other words, the production data 20 includes information for component mounting devices (solder printing device M1, component mounting devices M3 to M6, etc.) to perform the production work of mounted boards.

[0027] 3, the worker information 21 stores information about the workers W who work on the component mounting devices on the floor F, such as information about the ability category of the workers W, the number of workers W for each ability category, and the working hours of the workers W, including working hours and break times. The information about the ability category includes the type of work permitted to the workers W for each ability category, standard working times for replacing components, recovery work for device errors, etc.

[0028] 3, floor information 22 stores information about the configuration of floor F, line information about component mounting lines L1 to L3 equipped on floor F, etc. The line information includes information about the configuration of component mounting lines L1 to L3, the models of component mounting devices (solder printing device M1, component mounting devices M3 to M6, etc.) equipped on each component mounting line L1 to L3, information about equipment elements of the component mounting devices (tape feeders, tray feeders, mounting heads, suction nozzles, etc.), etc. Floor information 22 includes information about existing floor F with a production track record, as well as information for consideration of new floors where new component mounting lines L1 to L3 have been added to existing floor F, and new floors where new component mounting devices have been added to component mounting lines L1 to L3.

[0029] Specification information 23 stores information related to the specifications of component mounting devices that can be used on component mounting lines L1 to L3. For example, specification information 23 for component mounting devices M3 to M6 includes, for each model name, the number of conveyors, the number of component supply units, the number of mounting heads, the number of mountable tape feeders, as well as chips per hour (hereinafter referred to as "CPH"), which is the number of components that can be mounted per unit time as production capacity. For example, the maximum value of CPH (ideal CPH), which is the maximum performance that can be achieved by combining the equipment elements (tape feeders, tray feeders, mounting heads, suction nozzles, etc.) that component mounting devices M3 to M6 have, is stored as CPH.

[0030] 3, event information 24 stores information about events that require work by worker W on component mounting lines L1 to L3 (such as replenishing components D and recovering from equipment errors) and their occurrence frequency. The occurrence frequency is set for each model of component mounting equipment for a combination of multiple equipment elements based on the number of work mistakes and the number of operational errors included in operation performance 25, which will be described later, or based on experience.

[0031] The performance record collection unit 11 periodically collects performance records of component mounting work from a plurality of component mounting devices on component mounting lines L1 to L3 installed on floor F, and stores the collected performance records in storage unit 17 as operation performance records 25. For example, the performance records of component mounting work include information such as the production start date and time, production end date and time, changeover time, type of mounted board and the number of boards produced, the number of work mistakes, the mistake rate (frequency), the number of operational errors and their details, and information about workers W who performed work on floor F (working hours, working hours, break times, number of people, work details, etc.).

[0032] 3, production capacity calculation unit 12 calculates actual production capacity, which is the actual value of production capacity, for each of component mounting lines L1 to L3 from operation results 25 collected over a predetermined period. Specifically, production capacity calculation unit 12 calculates the total number of components D (total number of mounted components) mounted on board B by component mounting lines L1 to L3 over a predetermined period. Furthermore, production capacity calculation unit 12 calculates the production time by subtracting non-operational time during which production is stopped, such as shift change time for worker W or break time, from the operation time of component mounting lines L1 to L3 (time from the start of production of the first board to the end of production of the last board). Then, production capacity calculation unit 12 calculates the actual value of CPH (actual CPH) obtained by dividing the total number of mounted components by the production time, as the actual production capacity.

[0033] Furthermore, production capacity calculation unit 12 calculates effective production time by further subtracting from the production time equipment downtime, such as time spent down due to an operational error in the component mounting device or time spent down due to a component shortage in the component mounting device. Production capacity calculation unit 12 then calculates the actual production capacity as CPH (effective CPH), which is the total number of components mounted divided by the effective production time. Information such as the calculated actual production capacity is stored in memory unit 17 as actual production capacity information 26.

[0034] In FIG. 3, the display processing unit 13 displays a new floor setting screen, a simulation setting screen, a simulation result display screen, etc., which will be described later, on the display unit 29, to support the administrator in setting the configuration of a new component mounting line that estimates the production capacity of the component mounting line, setting the simulation conditions, and analyzing the results.

[0035] Here, an example of a new floor setting screen 40 that the display processing unit 13 displays on the display unit 29 will be described with reference to Fig. 4. The new floor setting screen 40 is used when setting the configuration of a new floor for which production capacity is to be estimated, such as a new floor or a floor where component mounting devices have been added to an existing component mounting line to improve production capacity. In this example, an example will be described in which a new floor (new line addition 1) is set up by adding one component mounting line (line L5) to an existing floor F1 (see Fig. 5) that has four component mounting lines (lines L1 to L4).

[0036] 4, a new floor setting screen 40 is provided with a line designation area 41 and a line information display area 42. Arranged in the line designation area 41 are a line information setting frame 43, a floor name input field 44, an add line button 45, a setting execution button 46, and an end button 47. A floor name (add new line 1) of a floor to be newly created is input in the floor name input field 44. When the administrator operates the input unit 28 to press the add line button 45, the display processing unit 13 switches the display unit 29 to a line setting screen (not shown). In the line setting screen, the component mounting devices to be placed on the new line, the equipment elements of the component mounting devices, etc. are set.

[0037] The line information setting frame 43 displays information such as the line name, number of mounting devices, and number of stages of the component mounting line (lines L1 to L5) on the new floor being set. When the delete button corresponding to the line name is pressed in the line information setting frame 43, that component mounting line is deleted from the new floor. When the edit button is pressed, the display processing unit 13 switches the display unit 29 to a line setting screen for changing the configuration of that component mounting line.

[0038] 4, a line information display frame 48 is arranged in the line information display area 42. The line information display frame 48 is provided with a line selection tab 48a, a line configuration display field 48b, and display advance buttons 48c and 48d. When one of the line selection tabs 48a is selected, the selected component mounting line is displayed in the line configuration display field 48b. When the display advance buttons 48c and 48d are pressed, the component mounting devices displayed in the line configuration display field 48b are changed in order.

[0039] In this example, in FIG. 5, the line configuration display field 48b displays the component mounting devices M3 to M6 equipped on the component mounting line (line L5) on the new floor (new line addition 1) in the order in which they are connected. Component mounting devices M3 and M4 are component mounting devices of model "E1," while component mounting devices M5 and M6 are component mounting devices of model "E2." The component mounting device of model "E1" is equipped with two conveyors and two mounting heads, one at the front and one at the rear, aligned with the board transport direction, and has two stages. The component mounting device of model "E2" is equipped with two conveyors and one mounting head, one at the front and one at the rear, and has one stage.

[0040] For component mounters M3 to M6 displayed in the line configuration display field 48b, a table configuration display 48e showing the configuration of the front and rear component supply units, and a mounting head configuration display 48f showing the configuration of the mounting heads attached to the front and rear are displayed. In the table configuration display 48e, "c17" indicates that a cart capable of mounting 17 tape feeders, "c30" indicates that a cart capable of mounting 30 tape feeders, and "f13" indicates that a cart capable of mounting 13 tape feeders is installed in the component supply unit, and "t20" indicates that a tray feeder capable of mounting 20 trays is installed. In the mounting head configuration display 48f, "H16" indicates that a mounting head equipped with 16 suction nozzles, "H8" indicates that a mounting head equipped with 8 suction nozzles, and "H3" indicates that a mounting head equipped with 3 suction nozzles is installed.

[0041] 4, the table configuration and mounting head configuration are set based on the type and size of components D that component mounting devices M3 to M6 will mount on board B. When the setting execution button 46 is pressed, the floor information creation unit 14 creates line information for each component mounting line (lines L1 to L5) of the new floor (new line addition 1) set on the new floor setting screen 40, and stores this in the storage unit 17 as floor information 22 for the new floor. The line information included in the floor information 22 includes information on the equipment elements (tape feeders, tray feeders, mounting heads, suction nozzles, etc.) of the component mounting devices (component mounting devices M3 to M6). When the end button 47 is pressed, the display processing unit 13 ends the new floor setting work.

[0042] Next, an example of a simulation setting screen 50 displayed on the display unit 29 by the display processing unit 13 will be described with reference to FIG. 5. The simulation setting screen 50 is used when setting conditions for a simulation that estimates the production capacity of a component mounting line. In this example, a component mounting line to be simulated is set for each floor on which multiple component mounting lines are installed. The simulation setting screen 50 has a current floor selection frame 51, a current floor display area 51a, a new floor selection frame 52, a new floor display area 52a, a production plan selection frame 53, a production plan display area 53a, an execute button 54, and an end button 55.

[0043] When the manager operates the input unit 28 to select one existing floor with production records (hereinafter referred to as the "current floor") from the drop-down list displayed in the current floor selection frame 51, outline information about the current floor is displayed in the current floor display area 51a. The display processing unit 13 displays existing floors for which operation records 25 have been collected in the drop-down list of the current floor selection frame 51. The display processing unit 13 also displays information about the current floor included in the floor information 22 in the current floor display area 51a. In this example, "Floor F1" is selected as the current floor. The current floor display area 51a displays the line names (lines L1 to L4) of the component mounting lines equipped on the current floor and the number of component mounting devices equipped on each line.

[0044] In FIG. 5, when one new floor (hereinafter referred to as "new floor") is selected from the drop-down list in the new floor selection frame 52, general information about the new floor is displayed in the new floor display area 52a. The display processing unit 13 displays a list of new floors included in the floor information 22 in the drop-down list in the new floor selection frame 52. The display processing unit 13 also displays information about the new floor included in the floor information 22 in the new floor display area 52a. In this example, "Add new line 1" set in the new floor setting screen 40 shown in FIG. 4 is selected as the new floor.

[0045] When one production plan is selected from the drop-down list in the production plan selection frame 53, summary information about the selected production plan is displayed in the production plan display area 53a. The display processing unit 13 displays, in the drop-down list of the production plan selection frame 53, a list of production plans that have been produced on the current floor selected in the current floor selection frame 51, from among the production plans included in the production plan information 18. The display processing unit 13 also displays summary information about the production plans included in the production plan information 18 in the production plan display area 53a.

[0046] 5, in this example, "Existing Production Plan 1," which has a production record on "Floor F1," is selected as the production plan. "Existing Production Plan 1" plans to produce 500 mounting boards X1, 2000 mounting boards X2, 1500 mounting boards X3, and 800 mounting boards X4, in this order. When the execute button 54 is pressed, a simulation is executed by the optimization processing unit 15 and the production capacity estimation unit 16 to estimate production capacity under the conditions set on the simulation setting screen 50. When the end button 55 is pressed, the display processing unit 13 discards the conditions set on the simulation setting screen 50 and ends the process of setting the simulation conditions.

[0047] 3, optimization processing unit 15 creates production data 20 that optimizes the arrangement information of components D in the component supply unit of the component mounting device so as to reduce the production time in the set production plan. The created production data 20 is stored in storage unit 17. Furthermore, optimization processing unit 15 creates a production plan that changes the production order of mounted boards or changes the allocation of mounted boards to component mounting lines so as to reduce the production time. The created production plan is stored in storage unit 17 as production plan information 18.

[0048] 3, production capacity estimation unit 16 estimates the production capacity of a component mounting line based on the production plan, board information 19, production data 20, worker information 21, line information included in floor information 22, specification information 23, and event information 24. The production capacity estimated by production capacity estimation unit 16 is stored in storage unit 17 as estimated production capacity information 27.

[0049] Specifically, production capacity estimation unit 16 calculates the ideal production capacity by adding up the ideal CPH of all component mounting devices equipped in the component mounting line, based on the specifications of the component mounting devices included in specification information 23. In other words, the ideal production capacity represents the maximum performance of the component mounting line. Production capacity estimation unit 16 calculates the ideal CPH based on the line information and specification information 23.

[0050] 3, production capacity estimation unit 16 estimates the CPH (event-free CPH) as the non-event production capacity when an event occurs in which production stops due to a component D running out or an operational error in the component mounting device, requiring work by operator W. In other words, the non-event production capacity is the production capacity estimated assuming that these events do not occur. Production capacity estimation unit 16 estimates the non-event CPH by simulating component mounting work by the component mounting device based on board information 19, production data 20, and line information.

[0051] Furthermore, the production capacity estimation unit 16 estimates the CPH (event occurrence CPH) that takes into account the occurrence frequency of events that require work by worker W, which are included in the event information 24, as the event occurrence production capacity. In other words, the event occurrence production capacity is a production capacity estimated by taking into account the occurrence frequency of these events. Based on the board information 19, production data 20, worker information 21, line information, and event information 24, the production capacity estimation unit 16 estimates the event non-occurrence CPH by predicting the occurrence of stoppages due to operational errors in the component mounting device, stoppages due to a component shortage in the component mounting device, recovery work by worker W, work to supply components D by worker W, and the like.

[0052] Next, with reference to Figures 6 to 8, an example of a simulation result display screen will be described in which the display processing unit 13 displays on the display unit 29 the actual production capacity information 26 calculated by the production capacity calculation unit 12 and the estimated production capacity information 27 estimated by the production capacity estimation unit 16.

[0053] 6 is an example of a simulation result (current floor performance) screen 60 displayed on the display unit 29 by the display processing unit 13. The simulation result (current floor performance) screen 60 displays the ideal production capacity of the current floor (floor F1) set on the simulation setting screen 50 (FIG. 5), the performance production capacity calculated based on the operation performance 25, and the like. The simulation result (current floor performance) screen 60 is provided with a current floor performance display area 61, a current floor estimate display button 62, a new floor estimate display button 63, a condition change button 64, and an end button 65.

[0054] Information regarding the line name, total number of mounted components, ideal CPH, and actual production capacity for each component mounting line (lines L1 to L4) equipped on the current floor is displayed in the current floor performance display area 61. The current floor performance display area 61 also displays the floor production capacity (floor production capacity) which is the total production capacity of all component mounting lines equipped on the current floor.

[0055] 6, the current floor performance display area 61 displays information about actual production capacity, such as production time (days, hours), actual CPH, and a comparison of actual CPH with ideal CPH. The current floor performance display area 61 also displays information about actual production capacity, such as effective production time (days, hours), effective CPH, and a comparison of effective CPH with ideal CPH. The comparison of actual CPH or effective CPH with ideal CPH is an index that shows how much performance of the component mounting equipment has been extracted.

[0056] For example, the total number of mounted components of component D placed on board B in a specified period on the component mounting line (line L1) is "7,773,480 pieces," the ideal CPH is "275,500 pieces / hour," the actual CPH is "149,438 pieces / hour," which is "54%" compared to the ideal CPH, and the effective CPH is "166,042 pieces / hour," which is "60%" compared to the ideal CPH.

[0057] In Figure 6, when the Display Current Floor Estimate button 62 is pressed, the display processing unit 13 displays a simulation result (current floor estimate) screen 70 (Figure 7) on the display unit 29. When the Display New Floor Estimate button 63 is pressed, the display processing unit 13 displays a simulation result (new floor estimate) screen 80 (Figure 8) on the display unit 29. When the Change Condition button 64 is pressed, the display processing unit 13 displays a simulation setting screen 50 (Figure 5) on the display unit 29. When the End button 65 is pressed, the display processing unit 13 ends the production capacity estimation process.

[0058] Next, an example of a simulation result (current floor estimate) screen 70 displayed on the display unit 29 by the display processing unit 13 will be described with reference to Fig. 7. The simulation result (current floor estimate) screen 70 displays the ideal production capacity of the current floor (floor F1) set on the simulation setting screen 50 (Fig. 5), the event-occurring production capacity, the event-non-occurring production capacity estimated by the production capacity estimation unit 16, and the like. The simulation result (current floor estimate) screen 70 has a current floor estimate display area 71, a current floor performance display button 72, a new floor estimate display button 73, a condition change button 74, and an end button 75.

[0059] The current floor estimation display area 71 displays the line name, total number of mounted components, ideal CPH, information on the event-occurring production capacity, and information on the event-free production capacity for each component mounting line (lines L1 to L4) on the current floor. The current floor estimation display area 71 also displays the floor production capacity. The total number of mounted components and ideal CPH are the same as those on the simulation results (current floor performance) screen 60.

[0060] In FIG. 7, the current floor estimation display area 71 displays information about event-occurring production capacity, such as an estimated production time (days, hours), event-occurring CPH, and a comparison of event-occurring CPH with the ideal CPH. The current floor estimation display area 71 also displays information about non-event-occurring production capacity, such as an estimated effective production time (days, hours), event-non-occurring CPH, and a comparison of event-non-occurring CPH with the ideal CPH. The comparison of event-occurring CPH or event-non-occurring CPH with the ideal CPH is an index that estimates how much of the component mounting equipment's performance can be exploited. For example, the event-occurring CPH for the component mounting line (line L1) is 169,363 pieces / hour, which is 61% compared to the ideal CPH, and the non-event-occurring CPH is 188,181 pieces / hour, which is 68% compared to the ideal CPH.

[0061] In Figure 7, when the Display Current Floor Results button 72 is pressed, the display processing unit 13 displays the simulation results (current floor results) screen 60 (Figure 6) on the display unit 29. When the Display New Floor Estimate button 73 is pressed, the display processing unit 13 displays the simulation results (new floor estimate) screen 80 (Figure 8) on the display unit 29. When the Change Condition button 74 is pressed, the display processing unit 13 displays the simulation setting screen 50 (Figure 5) on the display unit 29. When the End button 75 is pressed, the display processing unit 13 ends the production capacity estimation process.

[0062] Next, an example of a simulation result (new floor estimation) screen 80 displayed on the display unit 29 by the display processing unit 13 will be described with reference to Fig. 8. The simulation result (new floor estimation) screen 80 displays the ideal production capacity of the new floor (new line addition 1) set on the simulation setting screen 50 (Fig. 5), the estimated event-occurring production capacity, the event-non-occurring production capacity, etc. The simulation result (new floor estimation) screen 80 has a new floor estimation display area 81, a current floor performance display button 82, a current floor estimation display button 83, a condition change button 84, and an end button 85.

[0063] The new floor estimation display area 81 displays the line name, total number of mounted components, ideal CPH, information about the event-occurring production capacity, and information about the event-free production capacity for each component mounting line (lines L1 to L5) on the new floor. The new floor estimation display area 81 also displays the floor production capacity. The total number of mounted components for each component mounting line is optimized by the optimization processing unit 15 so that mounted boards produced on the current floor can be optimally produced on the new floor. Therefore, although the total number of mounted components for each component mounting line differs between the current floor and the new floor, the total number of mounted components for the entire floor is the same on the current floor and the new floor.

[0064] 8, the new floor estimation display area 81 displays information about the event-occurring production capacity, such as an estimated value of the production time (number of days, hours), the event-occurring CPH, and a comparison of the event-occurring CPH with the ideal CPH. The new floor estimation display area 81 also displays information about the event-free production capacity, such as an estimated value of the effective production time (number of days, hours), the event-free CPH, and a comparison of the event-free CPH with the ideal CPH. For example, the total number of mounted components for component D mounted on board B assigned to the component mounting line (line L5) is "9,806,967 components," the ideal CPH is "446,400 components / hour," the event-occurring CPH is "306,468 components / hour," which is "69%" compared to the ideal CPH, and the event-free CPH is "340,520 components / hour," which is "76%" compared to the ideal CPH.

[0065] In Fig. 8, when the Display Current Floor Results button 82 is pressed, the display processing unit 13 displays the simulation results (current floor results) screen 60 (Fig. 6) on the display unit 29. When the Display Current Floor Estimates button 83 is pressed, the display processing unit 13 displays the simulation results (current floor estimates) screen 70 (Fig. 7) on the display unit 29. When the Change Conditions button 84 is pressed, the display processing unit 13 displays the simulation setting screen 50 (Fig. 5) on the display unit 29. When the End button 85 is pressed, the display processing unit 13 ends the production capacity estimation process.

[0066] In the above, an example has been described in which the simulation result display screen is displayed as three screens, namely, the simulation result (current floor actual) screen 60, the simulation result (current floor estimate) screen 70, and the simulation result (new floor estimate) screen 80, and these are switched between using the current floor actual display button 82, etc. However, the present invention is not limited to this example. For example, the current floor actual display area 61 of the simulation result (current floor actual) screen 60, the current floor estimate display area 71 of the simulation result (current floor estimate) screen 70, and the new floor estimate display area 81 of the simulation result (new floor estimate) screen 80 may be displayed on a single screen.

[0067] In this way, display unit 29 compares and displays the ideal production capacity, actual production capacity, event-occurring production capacity, and event-free production capacity of the estimated multiple component mounting lines. This allows for easy comparison of the production capacities of component mounting lines with different configurations. Furthermore, production capacity estimation unit 16 estimates the floor production capacity, which is the overall production capacity of the floor, and display unit 29 compares and displays the estimated multiple floor production capacities. Furthermore, production capacity includes the number of components that can be mounted on board B, which will become the mounting board, in a specified period of time (total number of mounted components). Furthermore, production capacity estimation unit 16 estimates production capacity under different conditions, such as the component mounting line configuration (line information), the production order of the mounted boards (production plan), the production time of the mounted boards (production plan), and the number of workers W (producer information 21).

[0068] Next, a production capacity estimation method (production capacity estimation program) for estimating the production capacity of component mounting lines L1 to L3, which are composed of multiple component mounting devices, to produce mounted boards will be described with reference to the flow of Fig. 9. First, performance record collection unit 11 collects operation performance records 25, which are the performance records of component mounting work, from multiple component mounting devices (component mounting devices M3 to M6) of component mounting lines L1 to L3 installed on floor F (ST1: operation performance collection step). Next, production capacity calculation unit 12 calculates the actual production capacity (total number of mounted components, actual CPH, effective CPH), which are the actual values ​​of production capacity, for each component mounting line L1 to L3 from the operation performance records 25 (ST2: production capacity calculation step).

[0069] Next, the following are acquired: a production plan (production plan information 18) for the mounted boards to be produced on the component mounting lines L1 to L3; board information 19 relating to the configuration of the mounted boards; production data 20 for the component mounting equipment to perform production work on the mounted boards; worker information 21 relating to the workers W who work on the component mounting equipment; line information (floor information 22) relating to the configuration of the component mounting lines L1 to L3; specification information 23 relating to the specifications of the component mounting equipment; and event information 24 relating to events that require work by workers W on the component mounting lines L1 to L3 and their frequency of occurrence (ST3: information acquisition process).

[0070] 9, optimization processing unit 15 then creates production data 20 by optimizing the arrangement information of components D in the component supply units of component mounting devices M3 to M6, and a production plan by optimizing the allocation of mounting boards to component mounting lines L1 to L3 and the production order, so as to reduce production time in the acquired production plan (ST4: optimization step). Next, production capacity estimation unit 16 estimates the production capacities (ideal production capacity, event-occurring production capacity, and event-nonoccurring production capacity) of component mounting lines L1 to L3 based on the acquired information and the optimized information (ST5: production capacity estimation step). Next, display processing unit 13 compares the multiple estimated production capacities and displays them on display unit 29 (ST6: display step) (e.g., FIGS. 6 to 8). This makes it easy to compare the production capacities of component mounting lines with different configurations.

[0071] When the conditions such as the configuration of floor F or component mounting lines L1 to L3, or the production plan are changed and the production capacity is estimated again (No in ST7), the information acquisition step (ST3) to the display step (ST6) are repeatedly executed. At that time, the simulation setting screen 50 (FIG. 5) or the like is used to input and change the simulation conditions.

[0072] As described above, the management computer 3 of this embodiment is a production capacity estimation system that includes a production capacity estimation unit 16 that estimates the production capacity of component mounting lines L1 to L3 based on the production plan for the mounted boards (production plan information 18), board information 19 related to the configuration of the mounted boards, production data 20 for the component mounting equipment, worker information 21 related to the worker W who works on the component mounting equipment, line information (floor information 22) related to the configuration of the component mounting lines L1 to L3, specification information 23 related to the specifications of the component mounting equipment, and event information 24 related to events that require work by worker W on the component mounting lines L1 to L3 and their frequency of occurrence, and a display unit 29 that compares and displays multiple estimated production capacities.

[0073] This makes it possible to easily compare the production capacities of component mounting lines with different configurations. [Industrial Applicability]

[0074] 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 production capacities of component mounting lines with different configurations, and are useful in the field of mounting components onto boards. [Explanation of symbols]

[0075] 3. Management computer (production capacity estimation system) B board D parts F Floor L1~L3 component mounting lines M3~M6 component mounting equipment (component mounting equipment) W Worker

Claims

1. A production capacity estimation system that estimates the production capacity of a component mounting line made up of a plurality of component mounting devices to produce mounted boards, a production capacity estimation unit that estimates the production capacity of the component mounting line based on a production plan for mounted boards to be produced in the component mounting line, board information related to the configuration of the mounted boards, production data for the component mounting devices to execute production work for the mounted boards, worker information related to workers who work on the component mounting devices, line information related to the configuration of the component mounting line, specification information related to the specifications of the component mounting devices, and event information related to events that require work by workers on the component mounting line and their occurrence frequency; a display unit that compares and displays the plurality of estimated production capacities, The production capacity estimation system, wherein the production capacity estimation unit estimates at least two of an ideal production capacity estimated based on the specifications of the component mounting device, an event-free production capacity estimated assuming that the event will not occur, and an event-occurrence production capacity estimated taking into account the frequency of occurrence of the event.

2. A production capacity estimation system that estimates the production capacity of a component mounting line composed of multiple component mounting devices to produce mounted boards, comprising: a production capacity estimation unit that estimates the production capacity of the component mounting line based on a production plan for mounted boards to be produced in the component mounting line, board information related to the configuration of the mounted boards, production data for the component mounting devices to execute production work for the mounted boards, worker information related to workers who work on the component mounting devices, line information related to the configuration of the component mounting line, specification information related to the specifications of the component mounting devices, and event information related to events that require work by workers on the component mounting line and their occurrence frequency; a display unit that compares and displays the plurality of estimated production capacities; a performance collection unit that collects operational performance data of the plurality of component mounting devices; a production capacity calculation unit that calculates an actual production capacity, which is an actual value of the production capacity, from the operation record, The display unit compares the estimated production capacity with the actual production capacity and displays the comparison result.

3. 3. The production capacity estimation system according to claim 1, wherein the line information includes information about facility elements of the component mounting device.

4. 4. The production capacity estimation system according to claim 1, wherein the production capacity estimation unit estimates the production capacity under different conditions for at least one of a configuration of the component mounting line, a production order of the mounted boards, a production time for the mounted boards, and a number of workers.

5. A plurality of the component mounting lines are arranged on the floor, the production capacity estimation unit estimates a floor production capacity, which is the overall production capacity of the floor; The production capacity estimation system according to claim 1 , wherein the display unit compares and displays the estimated floor production capacities.

6. The production capacity estimation system according to claim 1 , wherein the production capacity includes a number of components that can be mounted on the substrate that will become the mounting substrate in a predetermined period of time.

7. A production capacity estimation method for estimating a production capacity for producing mounted boards in a component mounting line made up of a plurality of component mounting devices, comprising: a production capacity estimation step of estimating the production capacity of the component mounting line based on a production plan for mounting boards to be produced in the component mounting line, board information relating to the configuration of the mounting boards, production data for the component mounting device to execute production work on the mounting boards, worker information relating to workers who work on the component mounting device, line information relating to the configuration of the component mounting line, specification information relating to the specifications of the component mounting device, and event information relating to events that require work by workers on the component mounting line and their occurrence frequency; a display step of comparing the estimated production capacities and displaying the results on a display unit, The production capacity estimation method includes estimating at least two of an ideal production capacity estimated based on the specifications of the component mounting device, a non-event production capacity estimated on the assumption that the event will not occur, and an event production capacity estimated taking into account the frequency of occurrence of the event.

8. A production capacity estimation method for estimating the production capacity of a component mounting line composed of a plurality of component mounting devices to produce mounted boards, comprising: a production capacity estimation step of estimating the production capacity of the component mounting line based on a production plan for mounting boards to be produced in the component mounting line, board information relating to the configuration of the mounting boards, production data for the component mounting device to execute production work on the mounting boards, worker information relating to workers who work on the component mounting device, line information relating to the configuration of the component mounting line, specification information relating to the specifications of the component mounting device, and event information relating to events that require work by workers on the component mounting line and their occurrence frequency; a display step of comparing the estimated production capacities and displaying the results on a display unit, a performance collection step of collecting operation performance data of the plurality of component mounting devices; and a production capacity calculation step of calculating an actual production capacity, which is an actual value of the production capacity, from the operation record, The display step compares the estimated production capacity with the actual production capacity and displays the results.

9. A production capacity estimation program that causes a computer to estimate a production capacity for producing mounted boards in a component mounting line made up of a plurality of component mounting devices, a production capacity estimation step of estimating the production capacity of the component mounting line based on a production plan for mounted boards to be produced in the component mounting line, board information relating to the configuration of the mounted boards, production data for the component mounting devices to execute production work on the mounted boards, worker information relating to workers who work on the component mounting devices, line information relating to the configuration of the component mounting line, specification information relating to the specifications of the component mounting devices, and event information relating to events that require work by workers on the component mounting line and their occurrence frequency; a display step of comparing the estimated production capacities and displaying the results on a display unit, The production capacity estimation step is a production capacity estimation program that estimates at least two of an ideal production capacity estimated based on the specifications of the component mounting device, an event-free production capacity estimated assuming that the event will not occur, and an event-occurrence production capacity estimated taking into account the frequency of occurrence of the event.

10. A production capacity estimation program that causes a computer to estimate the production capacity of a component mounting line composed of a plurality of component mounting devices to produce mounted boards, a production capacity estimation step of estimating the production capacity of the component mounting line based on a production plan for mounted boards to be produced in the component mounting line, board information relating to the configuration of the mounted boards, production data for the component mounting devices to execute production work on the mounted boards, worker information relating to workers who work on the component mounting devices, line information relating to the configuration of the component mounting line, specification information relating to the specifications of the component mounting devices, and event information relating to events that require work by workers on the component mounting line and their occurrence frequency; a display step of comparing the estimated production capacities and displaying the results on a display unit, a performance collection step of collecting operation performance data of the plurality of component mounting devices; A production capacity calculation step of calculating an actual production capacity, which is an actual value of the production capacity, from the operation record, The display step compares the estimated production capacity with the actual production capacity and displays the comparison result.

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