Production planning method and production planning device

Abstract

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

Description

[Technical Field]

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

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

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

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

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

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

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

[0008] The production plan creation device of the present invention creates a production plan for producing a plurality of types of mounted boards using a plurality of production lines, and includes: an approximate cycle time calculation unit that calculates, for each production line, an approximate cycle time required to produce each of the plurality of types of mounted boards on the production line; a production line allocation unit that allocates each of the plurality of types of mounted boards to one of the plurality of production lines based on the calculated approximate cycle time; a cycle time calculation unit that calculates the cycle time required to produce the allocated type of mounted board on the production line; a production plan update unit that creates a production plan based on the calculated cycle time; an evaluation index value calculation unit that calculates an evaluation index value for the created production plan; and an allocation change unit that changes the allocation of the types to the production lines based on the calculated evaluation index value. [Effects of the Invention]

[0009] According to the present invention, a production plan with high prediction accuracy and high production efficiency can be automatically created. [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 plan view of a component mounting device provided in a component mounting system according to an embodiment of the present invention; [Figure 4] FIG. 1 is a partial cross-sectional view of a component mounting device provided in a component mounting system according to an embodiment of the present invention. [Figure 5] FIG. 1 is a block diagram showing the configuration of a management computer (production plan creation device) according to an embodiment of the present invention. [Figure 6] FIG. 2 is an explanatory diagram of an example of production plan information used in a management computer (production plan creation device) according to an embodiment of the present invention; [Figure 7]FIG. 1 is an explanatory diagram of an example of cycle time information calculated in a management computer (production plan creation device) according to an embodiment of the present invention; [Figure 8] (a) (b) (c) is an explanatory diagram of an example of a product commonality calculated by a management computer (production plan creation device) according to an embodiment of the present invention. [Figure 9] 1A and 1B are explanatory diagrams illustrating an example of a production plan created by a management computer (a production plan creation device) according to an embodiment of the present invention. [Figure 10] 1 is a flow diagram of a production plan creation 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, component mounting device, etc.

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

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

[0014] A placement work support device 4 is placed in a preparation area As, which is different from the production area Ap and is provided on floor F. The placement work support device 4 is connected to a management computer 3 via a communication network 2. A replacement cart 5, which is the subject of placement work (described later), is connected to the placement work support device 4. A plurality of carts 5 in various states, such as before, during, or after placement work, are stored in the preparation area As. The preparation area As also stores 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 equipment arranged on floor F.

[0015] 1, a placement operation is performed on a carriage 5 connected to a placement operation support device 4 in accordance with work instructions corresponding to the type of mounted board to be produced on the component mounting lines L1 to L3. As part of the placement operation, workers perform tasks such as removing from the carriage 5 a plurality of tape feeders 9 and reels 17 that supply the specified components, and attaching them to the specified positions on the carriage 5. For carriages 5 in the preparation area As, including carriages 5 connected to the placement operation support device 4, placement operations can be performed in parallel with the production of mounted boards on the component mounting lines L1 to L3. Hereinafter, preparation work for a type change outside the component mounting lines L1 to L3, including placement work on carriages 5, will be referred to as off-site setup work.

[0016] When changing the type of mounted board produced on the component mounting lines L1 to L3, the worker moves the cart 5 that has completed placement work in the preparation area As to the component mounting line L1 to L3 and performs a product type changeover operation to replace it with the cart 5 attached to the component mounting device. In the product type changeover operation, the worker also moves 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 line L1 to L3 and replaces them. Hereinafter, the preparation work for a product type change within the component mounting lines L1 to L3, including the product type changeover operation of replacing the cart 5, will be referred to as internal setup work.

[0017] 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 production equipment such as board supply device M1, screen printing device M2, component mounting devices M3 to M6, reflow device M7, and board recovery device M8 in series from the upstream side (left side of the page) to the downstream side (right side of the page) in the board transport direction. Note that component mounting line L1 is a group of production equipment connected via communication network 2, and the production equipment does not have to be physically connected to each other.

[0018] The board supply device M1, screen printing device M2, component mounting devices M3 to M6, reflow device M7, and board removal device M8 are connected to a management computer 3 via a communication network 2. The board supply device M1 has a storage unit such as a rack that stores multiple boards, and performs a board supply operation by removing boards from the storage unit and supplying them to downstream equipment. The screen printing device M2 performs a solder printing operation by printing solder on boards carried in from upstream using a screen mask attached to the printing operation unit. Note that the component mounting line L1 may also include a solder application device that applies solder to boards using a dispenser, either installed alongside the screen printing device M2 or instead of the screen printing device M2. The screen printing device M2 and the solder application device are printing devices that deposit solder on boards.

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

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

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

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

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

[0024] In FIG. 3, Y-axis table 10 and beam 11 constitute mounting head moving mechanism 13, which moves mounting head 12 horizontally (X direction, Y direction). Mounting head moving mechanism 13 and mounting head 12 pick up components D by suction using suction nozzle 12b from the component removal position of tape feeder 9 attached to component supply unit 8. Then, mounting head moving mechanism 13 moves mounting head 12 to the mounting position of board B held by board transport mechanism 7, where it performs component mounting work. The time it takes for mounting head 12 to remove components D from tape feeder 9 and mount them on board B depends on the position of tape feeder 9 on carriage 5 (the configuration of the production equipment). For example, by positioning tape feeder 9, which supplies components D that are frequently mounted on board B, near the center of carriage 5, the movement distance of mounting head 12 can be reduced, thereby shortening the mounting time.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0040] In other words, estimated cycle time 36c is the cycle time required to produce that product type in the configuration of existing component mounting lines L1 to L3 without optimization such as the placement of tape feeders 9 and nozzle units 12a, or product standardization among multiple product types (lots). If there are detachable elements required to produce that product type, the estimated cycle time is calculated assuming that the required elements are present. Furthermore, if there is production equipment required to produce that product type, the estimated cycle time is calculated only for the component mounting lines equipped with that production equipment.

[0041] 5, the production line allocation unit 21b allocates lots (production types) to be produced to production lines (component mounting lines L1 to L3) based on information (production plan information 23a) about the lots (production types) to be produced, such as the estimated cycle time 36 and the number of sheets to be produced 33, and stores the information in the production plan information 23a. For example, the production line allocation unit 21b allocates each lot to the component mounting lines L1 to L3 so as not to cause a bias in the production time of the lot (production type) determined based on the estimated cycle time 36 and the number of sheets to be produced 33. In this case, the production line allocation unit 21b does not allocate the lot (production type) to the component mounting lines L1 to L3 where production is not possible and for which "-" is stored in the estimated cycle time 36.

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

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

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

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

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

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

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

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

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

[0051] 9(a) shows the updated production plan (production plan information 23a) in chronological order. On component mounting line L1, lots A and B are produced in this production order, and the carts 5 are exchanged during the changeover work before production of lots A and B begins. On component mounting line L2, grouped lots C, D, and E are produced in this production order, and before production of lot C begins, the changeover work involves installing the cart 5 commonly allocated for lots C, D, and E.

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

[0053] On component mounting line L3, grouped lots F and G are produced in this production order, and then lot H is produced. Before production of lot F begins, a changeover operation is performed to attach a carriage 5 commonly arranged for lots F and G, and before production of lot G begins, only a changeover operation is performed to replace some of the tape feeders 9 and reels 17 attached to the carriages 5 attached to component mounting devices M3 to M6. Furthermore, during the changeover operation before production of lot H begins, the carriage 5 is replaced.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0068] As explained above, management computer 3 of this embodiment is a production plan creation device that includes an approximate cycle time calculation unit 21a that calculates the approximate cycle time 36 required to produce multiple product types (lots) for each production line (component mounting lines L1 to L3), a production line allocation unit 21b that assigns the product types to be produced to the production lines based on the approximate cycle time 36 and information on the product types to be produced, and a production sequence creation unit 21c that creates a production sequence for the multiple product types assigned to each production line.This production plan creation device can automatically create production plans with high prediction accuracy and production efficiency.

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

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

[0071] 3. Management computer (production planning device) 12 Mounting head B board L1~L3 Component mounting lines (production lines) M2 Screen Printing Machine (Printing Machine, Production Equipment) M3~M6 component mounting equipment (production equipment)

Claims

1. A production planning method for creating a production plan for producing a plurality of types of mounting boards using a plurality of production lines, comprising: calculating, for each of the production lines, an estimated cycle time required to produce each of the plurality of types of mounting boards on the production line; assigning each of the plurality of types of mounting boards to one of the plurality of production lines based on the calculated approximate cycle time; Calculating the cycle time required to produce the allocated type of mounting board on the production line; Creating a production plan based on the calculated cycle time; calculating an evaluation index value for the created production plan, the evaluation index value being an index related to human resources necessary for production; The production planning method changes the allocation of the product types to the production lines based on the calculated evaluation index values.

2. The human resources required for production are the number of workers required per hour, The production planning method according to claim 1 .

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

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

5. running an optimization loop after changing the allocation of product types to the production lines; The optimization loop a step of grouping a plurality of types of mounting boards allocated to the production line; determining a configuration of production equipment for the production line that produces the grouped plurality of product types; 5. The production planning method according to claim 1.

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

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

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