Component mounting system

Abstract

The present invention provides a part mount system comprising: a part mount machine including a part supply unit having a plurality of attached feeders and a head unit having a plurality of suction nozzles; and a management system. The management system performs: a defect ratio recognition process of recognizing a defect ratio by feeder, which indicates a defect ratio of a suction state of a part by the plurality of suction nozzles for each of the plurality of feeders; a withdrawal target identification process of identifying a withdrawal target feeder to be withdrawn from the part supply unit among the plurality of feeders; and a replacement instruction process of outputting replacement instruction data indicating an instruction of replacement with a replacement feeder to the part supply unit in response to the withdrawal of the withdrawal target feeder. In the withdrawal target identification process, the management system extracts, from among high defect rate feeders having a defect ratio by feeder exceeding a predetermined threshold value, a defect-causing feeder that causes a defect in the suction state of the part by the plurality of suction nozzles and identifies the defect-causing feeder as the withdrawal target feeder.

Description

Technical Field

[0001] The present invention relates to a component mounting system including a component mounting machine that mounts components supplied by a feeder onto a substrate to produce a component-mounted substrate.

Background Art

[0002] A component mounting system includes a component mounting machine that mounts components onto a substrate such as a printed circuit board. The component mounting machine includes a component supply unit to which a plurality of feeders for supplying components are attached, and a head unit having a plurality of suction nozzles that suck the components supplied by the feeders and mount the sucked components onto the substrate. In the component mounting machine, a feeder that has become used due to component depletion or the like is recovered from the component supply unit, and a new feeder is replenished to the component supply unit in response to the recovery (see, for example, Patent Document 1). In the component mounting machine, by replacing a feeder that has become used due to component depletion or the like with a new feeder, the production of the component-mounted substrate can be continued.

[0003] In the component mounting machine, as the suction state of the components by the suction nozzles, defects such as suction failures and suction position displacements may occur. Defects in the suction state of the components by the suction nozzles reduce the productivity of the component-mounted substrate in the component mounting machine, affect the mounting accuracy of the components on the component-mounted substrate, and affect the quality of the component-mounted substrate.

[0004] Patent Document 1 does not disclose a technique for improving the productivity and quality of the component-mounted substrate in the component mounting machine, and there is room for improvement in this regard.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

[0006] The objective of the present invention is to provide a component mounting system that can improve the productivity of component-mounted substrates in a component mounting machine and enhance the quality of component-mounted substrates.

[0007] A component mounting system according to one aspect of the present invention includes a component supply unit equipped with a plurality of feeders for supplying components, a head unit having a plurality of suction nozzles for picking up components supplied by the plurality of feeders and mounting the picked-up components onto a substrate, a component mounting machine for producing component-mounted substrates on which components are mounted, and a management system for managing the production of the component-mounted substrates. The management system performs the following: a production process that controls the plurality of feeders and the head unit to produce the component-mounted substrates in the component mounting machine; a defect rate recognition process that recognizes the defect rate for each of the plurality of feeders regarding the defect rate of the component adsorption state by the plurality of suction nozzles, based on production status data indicating the production status of the component-mounted substrates in the component mounting machine; a recovery target identification process that extracts a defect-causing feeder that is the cause of the defect in the component adsorption state by the plurality of suction nozzles from among the high-defect-rate feeders whose feeder-specific defect rate exceeds a predetermined threshold, and identifies the defect-causing feeder as a feeder to be recovered from the component supply unit; and a replacement instruction process that outputs replacement instruction data indicating an instruction to replace a feeder to supply a feeder to the component supply unit in response to the recovery of the feeder to be recovered.

[0008] The object, features, and advantages of the present invention will become more apparent from the following detailed description and accompanying drawings. [Brief explanation of the drawing]

[0009] [Figure 1] This figure schematically shows the configuration of a component mounting system according to an embodiment of the present invention. [Figure 2] This is a side cross-sectional view showing the configuration of a component mounting machine in a mounting line provided in a component mounting system. [Figure 3]This is a schematic plan view showing a component supply unit installed in a component mounting machine. [Figure 4] This is a schematic plan view of a storage device included in a component mounting system. [Figure 5] This is a schematic plan view showing the exchange device provided in a component mounting system. [Figure 6] This is a flowchart showing the processing flow performed by the management system included in the component mounting system. [Figure 7] This is a flowchart showing the processing flow performed by the management system. [Figure 8] This diagram illustrates the production process and feeder monitoring process performed by the management system, using front views of the component supply unit and head unit of a component mounting machine. [Figure 9] This diagram illustrates the production status data acquisition and production status recognition processes performed by the management system. [Figure 10] This diagram illustrates the processes performed by the management system for identifying items to be collected and setting priorities. [Figure 11] This diagram illustrates the exchange sequence setting process performed by the management system. [Figure 12] This diagram illustrates the replacement instruction process performed by the management system. [Figure 13] This diagram illustrates the feeder placement process performed by the management system, using plan views of the storage and exchange equipment. [Figure 14] This diagram illustrates the recovery process in the replacement process performed by the management system, using plan views of the parts supply unit and replacement device. [Figure 15] This diagram illustrates the replenishment process in the replacement process performed by the management system, using plan views of the parts supply unit and replacement device. [Modes for carrying out the invention]

[0010] Hereinafter, a component mounting system according to an embodiment of the present invention will be described with reference to the drawings.

[0011] The component mounting system 1 shown in FIG. 1 is a system for producing a component mounting substrate on which components such as electronic components are mounted on a substrate such as a printed circuit board. The component mounting system 1 includes a plurality of mounting lines 2 including a component mounter 2B, a storage device 3, a replacement device 4, and a management system 5.

[0012] [Regarding the mounting line] Each of the plurality of mounting lines 2 is installed in a predetermined production area AR1 and includes a plurality of component mounters 2B arranged along the conveyance direction of the substrate. The plurality of mounting lines 2 are installed in the production area AR1 so as to be arranged at a predetermined interval from each other in a direction intersecting the conveyance direction of the substrate. In FIG. 1, an example is shown in which a total of eight mounting lines 2, namely, the first mounting line 2A1, the second mounting line 2A2, the third mounting line 2A3, the fourth mounting line 2A4, the fifth mounting line 2A5, the sixth mounting line 2A6, the seventh mounting line 2A7, and the eighth mounting line 2A8, are arranged side by side in a direction intersecting the conveyance direction of the substrate. Note that the number of mounting lines 2 and the installation positions in the production area AR1 are not particularly limited.

[0013] Each component mounter 2B in the plurality of mounting lines 2 will be described while referring to FIG. 2. Hereinafter, the directional relationship will be described using the XYZ orthogonal coordinate axes. The X-axis direction and the Y-axis direction are orthogonal to each other on the horizontal plane, and the Z-axis direction extends in the vertical direction orthogonal to both the X-axis direction and the Y-axis direction. The conveyance direction of the substrate between each component mounter 2B in the mounting line 2 coincides with the Y-axis direction.

[0014] The component mounter 2B is a device that mounts components on a substrate to produce a component mounting substrate. Before mounting the components by the component mounter 2B, a pattern of solder paste is printed on the substrate. The component mounter 2B includes a mounter main body 21, a conveyance conveyor 22, a component supply unit 23, and a head unit 26.

[0015] The mounting machine main body 21 is a housing having an internal space in which each part constituting the component mounting machine 2B is arranged. The conveying conveyor 22 extends in the Y-axis direction and is arranged in a substantially central region inside the mounting machine main body 21. The conveying conveyor 22 conveys the substrate in the Y-axis direction.

[0016] The head unit 26 mounts components on the substrate conveyed by the conveying conveyor 22. The head unit 26 takes out components from a plurality of feeders 25 attached to the component supply unit 23 and mounts the taken-out components on the substrate. The head unit 26 has a plurality of suction nozzles 261. The suction nozzle 261 is a holder capable of sucking and holding components. The suction nozzle 261 is communicable with any one of a negative pressure generator, a positive pressure generator, and the atmosphere via an electric switching valve. That is, by supplying negative pressure to the suction nozzle 261, it becomes possible to suck and hold the component by the suction nozzle 261, and then, by supplying positive pressure, the suction and holding of the component are released. In the head unit 26, the plurality of suction nozzles 261 suck the components supplied by the plurality of feeders 25 and mount the sucked components on the substrate.

[0017] The component supply unit 23 is positioned in the X-axis direction end region of the mounting machine body 21. The component supply unit 23 has an upper frame 231, a lower frame 232, and a rear frame 233 for forming a plurality of supply support parts 24 that support a feeder 25 for supplying components in an insertable and removable manner. The upper frame 231 is a plate-shaped frame that extends in the X-axis direction and the Y-axis direction. The upper frame 231 is positioned at one end of the mounting machine body 21 in the X-axis direction such that a portion of the region on one end in the X-axis direction is exposed outward from the mounting machine body 21, while a portion of the region on the other end in the X-axis direction is housed inside the mounting machine body 21. The lower frame 232 is a plate-shaped frame that extends in the X-axis direction and the Y-axis direction, and is positioned below the upper frame 231 in the Z-axis direction and opposite to the upper frame 231. The lower frame 232 has a projection 2321 that protrudes upward in the Z-axis direction from the region on the other end in the X-axis direction that is housed inside the mounting machine body 21. The rear frame 233 is a plate-shaped frame that extends in the Y-axis and Z-axis directions, and is positioned closer to the center of the mounting machine body 21 than the other ends of the upper frame 231 and lower frame 232 in the X-axis direction.

[0018] Figure 3 shows an example in which a parts supply unit 23 has multiple supply support sections 24a to 24j. Each of the multiple supply support sections 24a to 24j supports a feeder 25 in the parts supply unit 23 so that it can be inserted and removed. In the parts supply unit 23, the multiple supply support sections 24a to 24j are arranged in the Y-axis direction. By inserting and mounting the feeder 25 into each of these supply support sections 24a to 24j, multiple feeders 25 are arranged in the Y-axis direction. In the example in Figure 3, multiple feeders 25A to 25J are arranged in the Y-axis direction while being supported by each of the supply support sections 24a to 24j.

[0019] The feeder 25 is a parts supply device that supplies parts. The parts supply method of the feeder 25 is not particularly limited, as long as it is configured to supply parts. Examples of feeders 25 include a tape feeder that supplies parts using tape as a carrier, a tray feeder that supplies parts by moving a tray on which parts are placed, and a stick feeder that supplies parts by pushing them out of a cylindrical stick. Alternatively, a bulk feeder with a bulk cassette containing bulk parts, which is detachably attached, may be used as the feeder 25.

[0020] The following describes the case where a tape feeder is used as the feeder 25. The feeder 25 supplies parts by discharging a parts storage tape PT capable of storing multiple parts. The parts storage tape PT consists of a carrier tape PT1 having multiple storage compartments for storing parts, and a cover tape PT2 that is joined to the carrier tape PT1 so as to cover the storage compartments. The feeder 25 includes a feeder body 251, a reel support section 252, a tape discharging section 254, and a retrieval section 255.

[0021] The feeder body 251 has a tape delivery path 253. The tape delivery path 253 is the path through which the component storage tape PT is delivered, and has a component removal section 2531 between the upstream end and the downstream end in the delivery direction of the component storage tape PT. The reel support section 252 is located on the upstream end side of the tape delivery path 253 in the feeder body 251. The reel support section 252 supports the reel on which the component storage tape PT is wound.

[0022] The tape delivery unit 254 is composed of, for example, a sprocket and is located near the component removal unit 2531 of the tape delivery path 253. The tape delivery unit 254 unwinds the component storage tape PT from a reel supported by the reel support unit 252 and delivers the unwinded component storage tape PT along the tape delivery path 253. The operation of the tape delivery unit 254 is controlled by a control circuit mounted on the control board 259. As the component storage tape PT is delivered along the tape delivery path 253, the cover tape PT2 is peeled off from the carrier tape PT1 upstream of the component removal unit 2531. As a result, components are exposed on the carrier tape PT1 at the component removal unit 2531. The components exposed on the carrier tape PT1 can be removed by the head unit 26. In other words, the head unit 26 removes the components supplied by the feeder 25 from the component removal unit 2531.

[0023] Upstream of the parts removal section 2531, the cover tape PT2 that has been peeled off from the carrier tape PT1 is collected by the collection section 255. The collection section 255 is composed of, for example, a pair of rollers that are in contact with each other. In this case, the collection section 255 collects the cover tape PT2 in accordance with the rotation of the pair of rollers. The cover tape PT2 collected by the collection section 255 is stored in the collection box 2551.

[0024] After the head unit 26 has removed the components, the carrier tape PT1 is fed outward from the feeder 25 via the downstream end of the tape feed path 253 by the feed operation of the tape feed unit 254. The carrier tape PT1 fed outward from the feeder 25 is cut to a predetermined length by the tape cutter 23A located near the protrusion 2321 of the lower frame 232 in the component supply unit 23.

[0025] As shown in Figure 2, the feeder 25 has an upper positioning pin 256, a lower positioning pin 257, and a feeder-side connector 258. The upper positioning pin 256 and the lower positioning pin 257 are pins that protrude from one end of the feeder body 251 in the X-axis direction. The upper positioning pin 256 and the lower positioning pin 257 are spaced apart from each other in the Z-axis direction at one end of the feeder body 251 in the X-axis direction, with the upper positioning pin 256 positioned above the lower positioning pin 257. The end of the feeder body 251 in the X-axis direction has a stepped portion that is recessed on the other side in the X-axis direction relative to the portion where the upper positioning pin 256 and the lower positioning pin 257 are provided. The feeder-side connector 258 is provided on this stepped portion at the end of the feeder body 251 in the X-axis direction. The feeder-side connector 258 is a connector that is electrically connected to the control board 259.

[0026] Multiple supply support sections 24a to 24j for inserting and removing the feeder 25 are formed on the upper frame 231, lower frame 232, and rear frame 233 of the component supply unit 23. Each supply support section 24a to 24j includes an upper holding rail 241, a lower holding rail 242, an upper pin insertion hole 243, a lower pin insertion hole 244, and a unit-side connector 245.

[0027] Multiple upper holding rails 241 are formed on the lower surface of the upper frame 231, extending in the X-axis direction and arranged in the Y-axis direction. The upper holding rails 241 are rail members that guide the upper end of the feeder 25 when it is inserted into or removed from the supply support sections 24a to 24j. Multiple lower holding rails 242 are formed on the upper surface of the lower frame 232, extending in the X-axis direction and arranged in the Y-axis direction. The lower holding rails 242 are rail members that guide the lower end of the feeder 25 when it is inserted into or removed from the supply support sections 24a to 24j.

[0028] The upper pin insertion holes 243 are multiple holes formed in the upper end of the rear frame 233, aligned in the Y-axis direction. The upper pin insertion holes 243 allow the insertion of the upper positioning pin 256 of the feeder 25 when the feeder 25 is inserted into the supply support sections 24a to 24j. On the other hand, when the feeder 25 is removed from the supply support sections 24a to 24j, the insertion of the upper positioning pin 256 into the upper pin insertion holes 243 is released. The lower pin insertion holes 244 are multiple holes formed in the lower end of the rear frame 233, aligned in the Y-axis direction. The lower pin insertion holes 244 allow the insertion of the lower positioning pin 257 of the feeder 25 when the feeder 25 is inserted into the supply support sections 24a to 24j. On the other hand, when the feeder 25 is removed from the supply support sections 24a to 24j, the insertion of the lower positioning pin 257 into the lower pin insertion holes 244 is released. The feeder 25 is positioned relative to the supply support sections 24a to 24j by inserting the upper positioning pin 256 through the upper pin insertion hole 243 and the lower positioning pin 257 through the lower pin insertion hole 244.

[0029] The unit-side connectors 245 are provided in multiple locations along the Y-axis direction on the protrusions 2321 of the lower frame 232 and are connectors that are electrically connected to the control unit of the component mounting machine 2B. The unit-side connectors 245 are connected to the feeder-side connectors 258 of the feeder 25 when the feeder 25 is inserted into the supply support sections 24a to 24j.

[0030] During the production of component-mounted boards using the component mounting machine 2B, multiple types of components are mounted on each board. Furthermore, the types of components mounted differ depending on the type of board. Therefore, as shown in Figure 3, multiple feeders 25A to 25J for different component types are arranged in the Y-axis direction within the component supply unit 23, supported by their respective supply support sections 24a to 24j. In this case, the multiple feeders 25A to 25J are supported by their respective supply support sections 24a to 24j within the component supply unit 23 in an arrangement optimized based on the efficiency of component mounting onto the board by the head unit 26. Specifically, the arrangement of the multiple feeders 25A to 25J within the component supply unit 23 is set so that the amount of movement of the head unit 26 is minimized when components are mounted onto the board.

[0031] [Regarding storage equipment] As shown in Figure 1, the storage device 3 is installed in the preparation area AR2, which is adjacent to the production area AR1. The preparation area AR2 is adjacent to the production area AR1 in the X-axis direction, which intersects with the Y-axis direction, which is the direction in which substrates are transported between each component mounting machine 2B. In the preparation area AR2, workers and robotic operators prepare the feeders 25 to be supplied to each component supply unit 23 of each component mounting machine 2B in the multiple mounting lines 2. The workers and robotic operators replenish the prepared feeders 25 to be supplied in the storage device 3. The storage device 3 stores multiple feeders 25 of different component types in an arrangement in a predetermined direction. A retrieval device 30 is installed adjacent to the storage device 3 within the preparation area AR2. The retrieval device 30 is a device for receiving feeders 25 that have been retrieved from each component mounting machine 2B due to component shortages or other reasons. Although Figure 1 shows an example in which one storage device 3 and one retrieval device 30 are installed in the preparation area AR2, the number of devices installed is not limited to this. Multiple storage devices 3 and multiple recovery devices 30 may be installed in the preparation area AR2.

[0032] The storage device 3 will be described with reference to Figure 4. The storage device 3 comprises a storage device body 31 and a storage unit 32. The storage device body 31 is a housing having an internal space in which the storage unit 32 is arranged. The storage unit 32 has a plurality of storage support parts 321a to 321g arranged inside the storage device body 31. The plurality of storage support parts 321a to 321g are composed of rails extending in the X-axis direction and are arranged in line in the Y-axis direction. The plurality of storage support parts 321a to 321g support a plurality of feeders 25 of different component types so that they can be inserted and removed. In the example in Figure 4, the storage unit 32 stores a plurality of feeders 25A to 25G to be replenished, each supported by its respective storage support part 321a to 321g. In the storage unit 32, each feeder 25A to 25G is inserted into each storage support section 321a to 321g, so that multiple feeders 25A to 25G are arranged in a line along the Y-axis.

[0033] In the example shown in Figure 4, seven storage support sections 321a to 321g are arranged sequentially in the storage unit 32 from one end to the other in the Y-axis direction. Each storage support section 321a to 321g supports one of the feeders 25A to 25G. Insertion of each feeder 25A to 25G into each storage support section 321a to 321g in the storage unit 32 is performed by an operator or robot in the preparation area AR2. On the other hand, removal of each feeder 25A to 25G from each storage support section 321a to 321g in the storage unit 32 is performed from the production area AR1 side by the replacement device 4 described later or by an operator.

[0034] [About the exchange equipment] As shown in Figure 1, the exchange device 4 is a robot that can move within the production area AR1 to positions opposite the component supply unit 23 of each component mounting machine 2B in the multiple mounting lines 2, the storage unit 32 of the storage device 3, and the recovery device 30, respectively. The exchange device 4 performs the task of exchanging the feeder 25 between the component supply unit 23 of the component mounting machine 2B, the storage unit 32 of the storage device 3, and the recovery device 30. Note that the feeder 25 replacement work may also be performed by an operator, in which case the exchange device 4 is omitted. The following describes the case in which the exchange device 4 performs the feeder 25 replacement work.

[0035] While the exchange device 4 is in a position facing the storage device 3, it extracts the feeders 25 to be replenished to each component supply unit 23 of each component mounting machine 2B from the storage support sections 321a to 321g of the storage unit 32 and takes them into the storage unit 32. While the exchange device 4 is in a position facing each component mounting machine 2B, it extracts the feeders 25 from the supply support sections 24 that support the feeders 25 to be recovered in each component supply unit 23 and recovers them into the storage unit 23, and also inserts the feeders 25 to be replenished into the supply support sections 24 after recovery, using them as the replenishment destination. Furthermore, while the exchange device 4 is in a position facing the recovery device 30, it moves the feeders 25 to be recovered that have been recovered into the storage unit 30.

[0036] The exchange device 4 will be described with reference to Figure 5. The exchange device 4 comprises an exchange device body 41, an operating unit 42, and an exchange unit 43. The exchange device body 41 is a housing having an internal space in which the operating unit 42 and the exchange unit 43 are arranged.

[0037] The replacement unit 43 is a unit that supports multiple feeders 25 to be recovered from each component supply unit 23 of each component mounting machine 2B, and feeders 25 to be supplied to each component supply unit 23. In other words, the replacement unit 43 is a unit that supports multiple feeders 25 that are exchanged with each component supply unit 23. The replacement unit 43 has a plate-like shape that extends in the X-axis direction and the Y-axis direction, and multiple replacement support parts 431a to 431f are provided on its upper surface. The multiple replacement support parts 431a to 431f are composed of rails that extend in the X-axis direction and are arranged on the replacement unit 43 so as to be aligned in the Y-axis direction. The multiple replacement support parts 431a to 431f support the feeders 25 that are exchanged between the supply support parts 24a to 24j of each component supply unit 23 and between the storage support parts 321a to 321g of the storage unit 32 so as to be insertable and removable. In the exchange unit 43, feeders 25 are inserted into each of the exchange support sections 431a to 431f, so that multiple feeders 25 are arranged in a line along the Y-axis. In the example shown in Figure 5, six exchange support sections 431a to 431f are arranged sequentially in the Y-axis direction of the exchange unit 43 from one end to the other. The exchange unit 43 is movable within the exchange device body 41 in the Y-axis direction, which is the direction in which the multiple exchange support sections 431a to 431f are arranged, within a predetermined allowable movement range 432.

[0038] The operating unit 42 is a unit that performs the operation of moving the feeder 25 relative to the exchange unit 43. The operating unit 42 includes an arm portion 44 and a hand portion 45. The arm portion 44 is movable in the space above the exchange unit 43 within the exchange device body 41 in the Y-axis direction, which is the direction in which the multiple exchange support portions 431a to 431f are arranged. The hand portion 45 is a gripping body that is movably attached to the arm portion 44 and capable of gripping the feeder 25. The hand portion 45 is movable in the X-axis direction relative to the arm portion 44, in which the multiple exchange support portions 431a to 431f extend. The hand portion 45 moves in the Y-axis direction in conjunction with the movement of the arm portion 44, and also moves in the X-axis direction relative to the arm portion 44, within the space above the exchange unit 43 within the exchange device body 41. The hand portion 45 moves in the X-axis direction relative to the arm portion 44 while gripping the feeder 25, thereby moving the feeder 25 so that it can be inserted into and removed from each of the replacement support portions 431a to 431f on the replacement unit 43.

[0039] As the exchange device 4 is positioned opposite the storage device 3, when the exchange unit 43 is positioned opposite the storage unit 32, the exchange unit 43 moves in the Y-axis direction within a predetermined allowable movement range 432 so that the exchange support part 431 that supports the feeder 25 to be supplied to the parts supply unit 23 faces the storage support part 321 that supports the feeder 25 to be supplied to the parts supply unit 23. The arm part 44 moves in the Y-axis direction so that the hand part 45 is positioned above the exchange support part 431 that supports the feeder 25 to be supplied. Then, the hand part 45 moves along the X-axis direction from the storage device 3 side to the exchange device 4 side while gripping the feeder 25 to be supplied. In this case, the feeder 25 to be supplied moves so as to be pulled out from the storage support part 321 in the storage unit 32 and inserted into the exchange support part 531 that supports the feeder 25 to be supplied on the exchange unit 43.

[0040] As the exchange device 4 is positioned opposite each component mounting machine 2B, when the exchange unit 43 is positioned opposite each component supply unit 23, the exchange unit 43 moves in the Y-axis direction within a predetermined allowable movement range 432 so that the exchange support part 431, which is the destination for the retrieved feeder 25, faces the supply support part 24 of the collection source that supports the feeder 25 to be retrieved from each component supply unit 23 to the exchange unit 43. The arm part 44 moves in the Y-axis direction so that the hand part 45 is positioned above the exchange support part 431 of the destination. Then, the hand part 45 moves along the X-axis direction from the component mounting machine 2B side to the exchange device 4 side while gripping the feeder 25 to be retrieved. In this case, the feeder 25 to be retrieved moves so as to be pulled out from the supply support part 24 of the collection source in the component supply unit 23 and inserted into the exchange support part 431 of the destination on the exchange unit 43. As a result, the feeder 25 to be retrieved from the component supply unit 23 is retrieved onto the exchange unit 43.

[0041] Furthermore, the replacement unit 43 moves in the Y-axis direction within a predetermined allowable movement range 432 so that the replacement support part 431 that supports the feeder 25 to be replenished faces the supply support part 24, which is the supply destination for the feeder 25 to be replenished after the feeder 25 to be recovered has been removed from the parts supply unit 23. The arm part 44 moves in the Y-axis direction so that the hand part 45 is positioned above the supply source replacement support part 431. Then, the hand part 45, while gripping the feeder 25 to be replenished, moves along the X-axis direction from the replacement device 4 side to the parts mounting machine 2B side. In this case, the feeder 25 to be replenished moves so that it is removed from the supply source replacement support part 431 on the replacement unit 43 and inserted into the supply destination supply support part 24 in the parts supply unit 23. As a result, the feeder 25 to be replenished on the replacement unit 43 is supplied to the parts supply unit 23 so that it can be replaced with the feeder 25 to be recovered.

[0042] [About the management system] The management system 5 consists of one or more microcomputers equipped with a CPU (Central Processing Unit) as a processing unit for performing various calculations. The management system 5 is connected to each of the component mounting machines 2B, storage device 3, and exchange device 4 in a data communication manner. The management system 5 is a system that manages the production of component-mounted boards by each component mounting machine 2B in multiple mounting lines 2. When managing the production of component-mounted boards by each component mounting machine 2B, the management system 5 also manages the collection of feeders 25 to be recovered from each component supply unit 23 of each component mounting machine 2B, and the supply of feeders 25 to be replenished to each component supply unit 23.

[0043] As shown in the flowcharts in Figures 6 and 7, the management system 5 performs the following processes: production processing S1, feeder monitoring processing S2, production status data acquisition processing S3, production status recognition processing S4, recovery target identification processing S5, priority setting processing S6, replacement order setting processing S7, replacement instruction processing S8, feeder placement processing S9, and replacement processing S10.

[0044] <Production Processing> In production process S1, the management system 5 controls the component supply operation of each feeder 25A to 25J supported by each supply support section 24a to 24j of the component supply unit 23, the component picking operation of each suction nozzle 261 of the head unit 26, and the component mounting operation in each component mounting machine 2B of the multiple mounting lines 2. As a result, the management system 5 causes each component mounting machine 2B to produce component-mounted boards in production process S1.

[0045] As shown in Figure 8, we assume that a replacement feeder 25 capable of supplying the same type of part P as the feeder 25 to be recovered from the parts supply unit 23 is installed in the parts supply unit 23. In the example in Figure 8, the replacement feeder 25J is supported and installed on the supply support section 24j of the parts supply unit 23. In this case, while the feeder 25 to be recovered is recovered from the parts supply unit 23 and the replacement feeder 25 to be replenished in response to the recovery is completed, the management system 5 causes the replacement feeder 25J to supply the part P in production process S1. This allows the supply of part P from the replacement feeder 25J to continue while the replacement of the feeder 25 is being carried out in the parts supply unit 23.

[0046] Furthermore, for each component P supplied by the multiple feeders 25A to 25J supported by each supply support section 24a to 24j of the component supply unit 23, a simultaneous adsorption group is set, which indicates a group of at least two components P that are simultaneously adsorbed by multiple adsorption nozzles 261. In this case, as shown in Figure 8, the multiple feeders 25A to 25J supported by each supply support section 24a to 24j of the component supply unit 23 are configured as simultaneous adsorption feeders 25E, 25F, and 25G that supply the components P belonging to the simultaneous adsorption group. In this case, during production process S1, the management system 5 causes each component P belonging to the simultaneous adsorption group supplied by the simultaneous adsorption feeders 25E, 25F, and 25G to be simultaneously adsorbed by multiple adsorption nozzles 261. This increases the efficiency of the component adsorption operation of each adsorption nozzle 261 of the head unit 26, thereby improving the productivity of component mounting boards in the component mounting machine 2B.

[0047] <Feeder monitoring process> In the feeder monitoring process S2, the management system 5 monitors the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the parts supply unit 23.

[0048] Specifically, as shown in Figure 8, the management system 5 monitors whether there is a feeder 25H among the multiple feeders 25A to 25J that has output error information ER indicating that it is unable to supply component P (step S21 in Figure 6). The feeder 25 outputs error information ER if there is an abnormality in the communication state between the component mounting machine 2B and the feeder 25 via the feeder-side connector 258 and the unit-side connector 245 of the component supply unit 23. In addition, the feeder 25 outputs error information ER if there is an abnormality in the delivery state of the carrier tape PT1 by the tape delivery unit 254 during component supply operation, or if there is an abnormality in the recovery state of the cover tape PT2 peeled off from the carrier tape PT1 by the recovery unit 255.

[0049] If there is a non-supplying feeder 25H that has output error information ER in one of the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the parts supply unit 23 (YES in step S21), the management system 5 performs a non-supplying instruction process S211. In the non-supplying instruction process S211, the management system 5 outputs non-supplying instruction data DD1 indicating that the non-supplying feeder 25H should be retrieved from the supply support section 24h of the parts supply unit 23, and that a new feeder 25 should be supplied to the supply support section 24h of the parts supply unit 23 in accordance with the retrieval of the non-supplying feeder 25H. The management system 5 outputs the non-supplying instruction data DD1 to the exchange device 4 or the operator. By supplying a new feeder 25 in accordance with the non-supplying instruction data DD1 in response to the retrieval of the non-supplying feeder 25H from the parts supply unit 23, it is possible to resolve the non-supplying state of parts caused by the non-supplying feeder 25H.

[0050] Furthermore, in the feeder monitoring process S2, the management system 5 monitors whether there is a feeder 25I among the multiple feeders 25A to 25J that is subject to maintenance, as shown in Figure 8 (step S22 in Figure 6). The management system 5 recognizes as a feeder 25I among the multiple feeders 25A to 25J if the number of times parts are supplied, the number of times parts are inserted into or removed from the parts supply unit 23, the energizing time, etc. exceeds a predetermined threshold, or if it is time for periodic maintenance.

[0051] If there is a feeder 25I to be maintained among the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the parts supply unit 23 (YES in step S22), the management system 5 performs maintenance response instruction processing S221. In maintenance response instruction processing S221, the management system 5 outputs maintenance response instruction data DD2 indicating that the feeder 25I to be maintained should be retrieved from the supply support section 24i of the parts supply unit 23, and that a new feeder 25 should be supplied to the supply support section 24i of the parts supply unit 23 in accordance with the retrieved feeder 25I. The management system 5 outputs maintenance response instruction data DD2 to the exchange device 4 or the operator. By supplying a new feeder 25 in accordance with the maintenance response instruction data DD2 and the retrieval of the feeder 25I to be maintained from the parts supply unit 23, it is possible to resolve the situation in which parts cannot be supplied due to maintenance of the feeder 25.

[0052] <Production status data acquisition process> In the production status data acquisition process S3, the management system 5 acquires production status data D1 from each component mounting machine 2B, which indicates the current production status of component-mounted boards by each component mounting machine 2B according to the production process S1. As shown in Figure 9, the production status data D1 includes feeder identification information FID, component identification information PID, supply support position information SSP, productivity index value PIV, feeder-specific defect rate FFR, nozzle-specific defect rate NFR, mounting accuracy index value CPK, and component out-of-stock index value PNV.

[0053] The feeder identification information FID is information for identifying the types of the multiple feeders 25A to 25J that are mounted on the component supply unit 23. The component identification information PID is information for identifying the types of components supplied by each feeder 25A to 25J indicated by the feeder identification information FID. The supply support position information SSP is information indicating the position of each supply support part 24a to 24j that supports each feeder 25A to 25J in the component supply unit 23 of each component mounting machine 2B.

[0054] The productivity index value PIV is a value that indicates the productivity of component-mounted substrates in each component mounting machine 2B, and can be, for example, the current number of substrates produced in each component mounting machine 2B. The higher the productivity of component-mounted substrates in each component mounting machine 2B, the larger the productivity index value PIV will be. Assume that multiple feeders 25A to 25J supported by each supply support section 24a to 24j of the component supply unit 23 are equipped with simultaneous pick-up feeders 25E, 25F, and 25G. In this case, if a defect occurs in the supply condition of each component picked up simultaneously by multiple pick-up nozzles 261 by the simultaneous pick-up feeders 25E, 25F, and 25G, the productivity index value PIV will fall below a predetermined standard value.

[0055] The feeder-specific defect rate FFR indicates the defect rate of the component suction state by the multiple suction nozzles 261 for each of the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the component supply unit 23. Specifically, the feeder-specific defect rate FFR indicates the ratio of the number of times each of the multiple feeders 25A to 25J was used in a situation where the component suction state by the multiple suction nozzles 261 was poor, relative to the total number of times it was used during a predetermined specified period. A poor component suction state by the suction nozzles 261 refers to a situation where defects such as suction errors or misalignment of the suction position occur. When looking at each of the multiple feeders 25A to 25J, as the feeder-specific defect rate FFR increases, the number of times it was used in a situation where the component suction state by the suction nozzles 261 was poor increases. Therefore, among the multiple feeders 25A to 25J, the feeder 25 with a high feeder-specific defect rate FFR can be a factor in the poor component suction state by the suction nozzles 261.

[0056] The Nozzle-Specific Failure Rate (NFR) indicates the failure rate of the component suction state by each of the multiple suction nozzles 261 mounted on the head unit 26. Specifically, the Nozzle-Specific Failure Rate (NFR) indicates the ratio of the number of times each of the multiple suction nozzles 261 was used in a situation where the component suction state was poor, relative to the total number of times it was used during a predetermined specified period. When viewed for each of the multiple suction nozzles 261, as the Nozzle-Specific Failure Rate (NFR) increases, the number of times it was used in a situation where the component suction state was poor increases. Therefore, among the multiple suction nozzles 261, the suction nozzle 261 with a high Nozzle-Specific Failure Rate (NFR) may be a cause of poor component suction state.

[0057] The mounting accuracy index value CPK indicates a value that serves as an indicator of the mounting accuracy of components on a component-mounted substrate produced by the component mounting machine 2B, for each of the multiple feeders 25A to 25J supported by each supply support section 24a to 24j of the component supply unit 23. The mounting accuracy index value CPK is expressed, for example, as the process capability index CPK, which quantifies the ability to mount components so that the misalignment of the component mounting position on the component-mounted substrate remains within an acceptable range. Among the multiple feeders 25A to 25J, a feeder 25 in which the mounting accuracy index value CPK, expressed as a process capability index, is less than "1.00" is assumed to have been used in a situation where the misalignment of the component mounting position on the component-mounted substrate was not within an acceptable range. Such a feeder 25 can be a factor in the deterioration of the quality of the component-mounted substrate.

[0058] The component shortage index PNV represents a value that serves as an indicator of component shortage prediction for each of the multiple feeders 25A to 25J supported by each supply support section 24a to 24j of the component supply unit 23. The component shortage index PNV is expressed, for example, as the number of remaining components in each of the multiple feeders 25A to 25J. In the multiple feeders 25A to 25J, as the component shortage index PNV increases, the time until a component shortage occurs increases.

[0059] <Production status recognition processing> As shown in Figure 6, in the production status recognition process S4, the management system 5 performs productivity recognition process S41, defect rate recognition process S42, mounting accuracy recognition process S43, and parts shortage recognition process S44.

[0060] In the productivity recognition process S41, the management system 5 recognizes the productivity index value PIV, which is an indicator of the productivity of the component mounting board in the component mounting machine 2B, based on the production status data D1. As previously described, when simultaneous pick-up feeders 25E, 25F, and 25G are set in the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the component supply unit 23, the productivity index value PIV correlates with the supply status of components by the simultaneous pick-up feeders 25E, 25F, and 25G. That is, if a defect occurs in the supply status of components by the simultaneous pick-up feeders 25E, 25F, and 25G, the productivity index value PIV falls below a predetermined standard value. For this reason, the management system 5 determines whether or not the productivity index value PIV falls below a predetermined standard value (step S411 in Figure 7).

[0061] If the productivity index value PIV falls below a predetermined standard value, it is assumed that the supply status of each part simultaneously picked up by the multiple suction nozzles 261 by the simultaneous suction feeders 25E, 25F, and 25G is defective, for example, that the parts are not supplied to the normal position or that the orientation of the parts is not normal. Therefore, if the productivity index value PIV falls below a predetermined standard value (YES in step S411), the management system 5 performs the re-installation instruction process S412. In the re-installation instruction process S412, the management system 5 outputs re-installation instruction data DD3 indicating an instruction to re-install the simultaneous suction feeders 25E, 25F, and 25G to the parts supply unit 23. The management system 5 outputs the re-installation instruction data DD3 to the exchange device 4 or the operator. By re-installing the simultaneous suction feeders 25E, 25F, and 25G to the parts supply unit 23 according to the re-installation instruction data DD3, it is possible to improve the supply status of parts by the simultaneous suction feeders 25E, 25F, and 25G. If the supply of components by the simultaneous adsorption feeders 25E, 25F, and 25G is improved, the productivity index PIV will not fall below a predetermined standard value, and the productivity of component-mounted substrates in the component mounting machine 2B will improve.

[0062] After processing the re-installation instruction process S412, the management system 5 determines whether the productivity index value PIV falls below a predetermined standard value (step S413 in Figure 7). If, after processing the re-installation instruction process S412, the productivity index value PIV still falls below the predetermined standard value, it is assumed that even if the simultaneous adsorption feeders 25E, 25F, and 25G are re-installed on the parts supply unit 23, the supply status of parts by the simultaneous adsorption feeders 25E, 25F, and 25G will not improve. Therefore, if, after processing the re-installation instruction process S412, the productivity index value PIV falls below the predetermined standard value (YES in step S413), the management system 5 performs the simultaneous adsorption response instruction process S414. In the simultaneous adsorption response instruction process S414, the management system 5 outputs simultaneous adsorption response instruction data DD4, which indicates an instruction to retrieve the simultaneous adsorption feeders 25E, 25F, and 25G from the parts supply unit 23 and to replenish the parts supply unit 23 with new feeders 25 in accordance with the retrieval. The management system 5 outputs simultaneous suction instruction data DD4 to the exchange device 4 or the operator. According to the simultaneous suction instruction data DD4, a new feeder 25 is supplied in response to the retrieval of simultaneous suction feeders 25E, 25F, and 25G from the component supply unit 23. This makes it possible to eliminate simultaneous suction failures by multiple suction nozzles 261 caused by poor component supply conditions of the simultaneous suction feeders 25E, 25F, and 25G. As a result, the productivity index value PIV does not fall below a predetermined standard value, and the productivity of component-mounted substrates in the component mounting machine 2B is improved.

[0063] In the defect rate recognition process S42, the management system 5 recognizes the feeder-specific defect rate FFR, which is shown for each of the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the parts supply unit 23, based on the production status data D1, regarding the defect rate of the parts adsorption state by the multiple adsorption nozzles 261. Furthermore, in the defect rate recognition process S42, the management system 5 recognizes the nozzle-specific defect rate NFR, which is shown for each of the multiple adsorption nozzles 261, based on the production status data D1, regarding the defect rate of the parts adsorption state by the multiple adsorption nozzles 261.

[0064] In the mounting accuracy recognition process S43, the management system 5 recognizes, based on the production status data D1, a mounting accuracy index value CPK, which is an indicator of the mounting accuracy of components on a component mounting board produced by the component mounting machine 2B, for each of the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the component supply unit 23.

[0065] In the parts shortage recognition process S44, the management system 5 recognizes a parts shortage index value PNV, which is an indicator for predicting parts shortages, for each of the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the parts supply unit 23.

[0066] <Processing to identify items to be recalled> After the processing of the defect rate recognition process S42, the mounting accuracy recognition process S43, and the parts shortage recognition process S44, which are included in the production status recognition process S4, the management system 5 performs the recall target identification process S5. In the recall target identification process S5, the management system 5 identifies the feeder 25 to be recalled from the parts supply unit 23 from among the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the parts supply unit 23.

[0067] Specifically, as shown in Figure 10, the management system 5 extracts high-defect rate feeders 25A to 25D from among the multiple feeders 25A to 25J whose feeder-specific defect rate FFR exceeds a predetermined first threshold. Then, from among the high-defect rate feeders 25A to 25D, the management system 5 extracts the defective feeders 25A to 25C that are the cause of poor component adsorption by the multiple adsorption nozzles 261, and identifies these defective feeders 25A to 25C as feeders 25 to be recovered from the component supply unit 23. At this time, the management system 5 extracts the defective feeders 25A to 25C from among the high-defect rate feeders 25A to 25D based on the feeder-specific defect rate FFR and the nozzle-specific defect rate NFR. In this way, the management system 5 can accurately extract the defective feeders 25A to 25C from among the high-defect rate feeders 25A to 25D. Specifically, among the high-defect-rate feeders 25A to 25D, the management system 5 extracts feeders 25A to 25C that have a subtraction value obtained by subtracting the nozzle-specific defect rate NFR from the feeder-specific defect rate FFR that exceeds a predetermined second threshold.

[0068] Furthermore, among the high-defect-rate feeders 25A to 25D, the management system 5 determines that feeder 25D, where the subtraction value obtained by subtracting the nozzle-specific defect rate NFR from the feeder-specific defect rate FFR is below a predetermined second threshold, is not a cause of poor component suction by the suction nozzle 261. The management system 5 then determines that the main reason why the feeder-specific defect rate FFR corresponding to feeder 25D exceeds a predetermined first threshold is the suction nozzle 261 used to pick up the components supplied by feeder 25D. In this case, the management system 5 may issue an instruction to the operator to perform maintenance such as cleaning or replacing the suction nozzle 261 corresponding to feeder 25D.

[0069] When the management system 5 identifies the defective feeders 25A to 25C as feeders 25 to be recovered from the parts supply unit 23, it assigns ranks to the defective feeders 25A to 25C according to the mounting accuracy index value CPK, as shown in Figure 10. Specifically, the management system 5 assigns rank A to feeder 25A whose mounting accuracy index value CPK is less than a predetermined third threshold, and rank B to feeders 25B and 25C whose mounting accuracy index value CPK is equal to or greater than the predetermined third threshold. When the mounting accuracy index value CPK is expressed as a process capability index, the third threshold is set to "1.00". If there are multiple defective feeders 25 to which rank A and rank B are assigned, the management system 5 subdivides rank A and rank B in descending order of feeder-specific defect rate FFR. In the example shown in Figure 10, the management system 5 assigns rank B1 to the feeder 25B with a higher feeder-specific failure rate FFR and rank B2 to the feeder 25C with a lower feeder-specific failure rate FFR, for two feeders 25B and 25C whose mounting accuracy index value CPK is above a predetermined third threshold.

[0070] The management system 5 assigns ranks to the defective feeders 25A to 25C according to the mounting accuracy index value CPK, thereby allowing the defective feeders 25A to 25C to be ranked according to the mounting accuracy of components on the component mounting board based on the mounting accuracy index value CPK. A defective feeder 25A, which has a mounting accuracy index value CPK below a predetermined third threshold and is assigned the first rank A, is assumed to be a cause of poor component suction by the suction nozzle 261 and was used in a situation where the misalignment of the component mounting position on the component mounting board was outside the acceptable range. In this case, a defective feeder 25A assigned the first rank A may be a cause of deterioration in the quality of the component mounting board. On the other hand, defective feeders 25B and 25C, which have a mounting accuracy index value CPK above a predetermined third threshold and are assigned the second rank B1 and second rank B2 respectively, are assumed to have been used in a situation where the misalignment of the component mounting position on the component mounting board was within the acceptable range. In this case, the defective feeders 25B and 25C, which are assigned second rank B1 and second rank B2 respectively, may be a cause of poor component suction by the suction nozzle 261, but they do not cause a decrease in the quality of the component-mounted substrate.

[0071] Furthermore, in the recall target identification process S5, the management system 5 extracts the parts-out-of-stock feeders 25E and 25F, which are predicted to be out of stock, from among the multiple feeders 25A to 25J supported by each of the supply support sections 24a to 24j of the parts supply unit 23, based on the parts-out-of-stock index value PNV. The management system 5 then identifies the parts-out-of-stock feeders 25E and 25F, along with the faulty feeders 25A to 25C, as feeders 25 to be recalled from the parts supply unit 23.

[0072] <Priority setting process> After the recall target identification process S5 is completed, the management system 5 performs the priority setting process S6. In the priority setting process S6, the management system 5 sets the priority for replacing the feeder 25 in the parts supply unit 23 corresponding to the defective feeder 25A to 25C, based on the rank assigned to the defective feeder 25A to 25C.

[0073] In the example shown in Figure 10, the management system 5 sets the priority for replacing feeders 25 corresponding to the defective feeders 25A to 25C as follows: the priority for replacing the defective feeder 25A, which has been assigned rank 1A, is set as the highest priority (1st priority); the priority for replacing the defective feeder 25B, which has been assigned rank 2B1, is set as the second priority; and the priority for replacing the defective feeder 25C, which has been assigned rank 2B2, is set as the third priority.

[0074] <Exchange sequence setting process> After the priority setting process S6 is completed, the management system 5 performs the replacement order setting process S7. In the replacement order setting process S7, the management system 5 sets the replacement order of the feeders 25 in the parts supply unit 23 corresponding to the faulty feeders 25A to 25C and the parts-out feeders 25E and 25F, and creates the replacement target list LA in Figure 11, which includes the replacement order.

[0075] Specifically, the management system 5 calculates the allowable time for replacing the feeder 25, OPT, which indicates the time allowed for replacing the feeder 25, corresponding to each of the out-of-parts feeders 25E and 25F, based on the out-of-parts index value PNV. Then, the management system 5 sets the replacement order of the feeders 25 corresponding to the faulty feeders 25A to 25C and the out-of-parts feeders 25E and 25F, based on the replacement priority according to the rank assigned to the faulty feeders 25A to 25C and the allowable time for replacing the feeder 25 corresponding to the out-of-parts feeders 25E and 25F, OPT. At this time, the management system 5 sets the replacement order of the feeders 25 in the parts supply unit 23 so that the replacement of the feeders 25 corresponding to the out-of-parts feeders 25E and 25F by the replacement device 4 is completed within the allowable time for replacing the feeder 25.

[0076] In the example shown in Figure 11, the management system 5 sets the replacement sequence corresponding to the defective feeder 25A, which has been assigned rank 1A, as the first step, the replacement sequences corresponding to the component-out feeders 25E and 25F as the second and third steps, respectively, and the replacement sequences corresponding to the defective feeders 25B and 25C, which have been assigned ranks 2B1 and 2B2, as the fourth and fifth steps, respectively. As previously mentioned, the defective feeder 25A, which has been assigned rank 1A, can be a factor in the deterioration of the quality of the component-mounted board. For this reason, the replacement sequence corresponding to the defective feeder 25A, which has been assigned rank 1A, is set as the first step, higher than the replacement sequences corresponding to the component-out feeders 25E and 25F. On the other hand, the defective feeders 25B and 25C, which have been assigned ranks 2B1 and 2B2, do not cause a deterioration of the quality of the component-mounted board. Therefore, the replacement sequence for the defective feeders 25B and 25C, which have been assigned ranks 2B1 and 2B2, is set lower than the replacement sequence for the component-depleted feeders 25E and 25F, being the 4th and 5th positions.

[0077] The management system 5 may set the replacement order of the feeders 25 corresponding to the faulty feeders 25A to 25C and the parts-out feeders 25E and 25F so that the amount of movement of the replacement unit 43 of the replacement device 4 in the replacement process S10 described below falls within a predetermined target range. In this case, the management system 5 sets the replacement order corresponding to the faulty feeder 25A, which has been assigned the first rank A, as the highest rank (1st). Then, for the replacement order corresponding to the faulty feeders 25B and 25C, which have been assigned the second ranks B1 and B2, and the parts-out feeders 25E and 25F, the management system 5 sets the order so that the amount of movement of the replacement unit 43 falls within a predetermined target range and is as small as possible, while taking into consideration that the replacement of the parts-out feeders 25E and 25F is completed within the parts-out replacement allowable time OPT. This makes it possible to improve the efficiency of replacing the feeders 25 with the parts supply unit 23 by the replacement device 4 in the replacement process S10.

[0078] When the replacement order of the feeders 25 in the parts supply unit 23 is set, the management system 5 creates a replacement target list LA. The replacement target list LA is data that shows the feeders 25 to be recovered from the parts supply unit 23, specifically the defective feeders 25A to 25C and the parts-out feeders 25E and 25F, in a list format in the order of replacement. For example, the replacement target list LA includes feeder identification information FID, part identification information PID, supply support position information SSP, feeder-specific defect rate FFR, and mounting accuracy index value CPK, corresponding to each of the defective feeders 25A to 25C and the parts-out feeders 25E and 25F, as well as the parts-out replacement allowable time OPT corresponding to the parts-out feeders 25E and 25F.

[0079] Once the list of items to be replaced LA is created, the management system 5 performs preparation instruction processing S71 as shown in Figure 7. In preparation instruction processing S71, the management system 5 outputs preparation instruction data D3 indicating the preparation of the feeders 25 to be replenished so that the feeders 25 to be replenished, which will be supplied to the parts supply unit 23 in response to the retrieval of the faulty feeders 25A to 25C and the parts-out feeders 25E and 25F, which are the feeders 25 to be retrieved, will be stored in the storage unit 32 of the storage device 3. The management system 5 outputs preparation instruction data D3 to the workers and work robots performing work in the preparation area AR2. By preparing the feeders 25 to be replenished according to the preparation instruction data D3, the feeders 25 to be replenished are stored in the storage unit 32 of the storage device 3. Specifically, the workers and work robots perform the work of preparing the feeders 25 to be replenished in the preparation area AR2 based on the preparation instruction data D3, and then perform the work of inserting the prepared feeders 25 into a predetermined storage support section 321 in the storage unit 32. As a result, the feeder 25 to be resupplied is stored in the storage unit 32.

[0080] <Replacement instruction processing> After the replacement sequence setting process S7 is completed, the management system 5 performs the replacement instruction process S8. In the replacement instruction process S8, the management system 5 outputs replacement instruction data D2 indicating the instruction to replace the feeder 25 to be replenished to the parts supply unit 23, in accordance with the recovery of the defective feeders 25A to 25C and the parts-out feeders 25E and 25F, which are the feeders 25 to be recovered. The management system 5 outputs the replacement instruction data D2 to the replacement device 4 or the operator.

[0081] Specifically, the management system 5 creates the exchange instruction list LB shown in Figure 12. The exchange instruction list LB is data that associates the information to be retrieved LB1, the storage source information LB2, and the information to be replenished LB3, and shows them in list format in the order of exchange.

[0082] The recall target information LB1 is information about the feeder 25 to be recalled in the component supply unit 23 of the component mounting machine 2B. The recall target information LB1 is associated with the replacement order of the defective feeders 25A to 25C and the component-out feeders 25E and 25F, which are the feeders 25 to be recalled. The recall target information LB1 includes feeder identification information FID, component identification information PID, and supply support position information SSP, corresponding to each of the defective feeders 25A to 25C and the component-out feeders 25E and 25F. The storage source information LB2 is information indicating the storage source where the feeder 25 to be replenished is stored. The storage source information LB2 includes unit name information UN, which indicates the unit name of the storage unit 32 where the feeder 25 to be replenished is stored, and storage support position information STSP, which indicates the location of the storage support 321 that supports the feeder 25 to be replenished in the storage unit 32. The replenishment target information LB3 is information about the feeder 25 to be replenished. The supply target information LB3 includes feeder identification information FID and component identification information PID corresponding to the feeder 25 to be supplied.

[0083] The management system 5 outputs replacement instruction data D2, which includes the created replacement instruction list LB. According to the replacement instruction data D2, the feeders 25 to be replenished are supplied in response to the recovery of the faulty feeders 25A to 25C from the component supply unit 23, thereby improving the poor component suction state by the suction nozzle 261 caused by the faulty feeders 25A to 25C. This makes it possible to improve the productivity of component-mounted boards in the component mounting machine 2B and to improve the quality of the component-mounted boards. Furthermore, according to the replacement instruction data D2, it is possible to recover the component-depleted feeders 25E and 25F from the component supply unit 23 and replenish the feeders 25 to be replenished to the component supply unit 23 in response to their recovery. This makes it possible to avoid the interruption of component supply caused by the component-depleted feeders 25E and 25F, and thus to continue production of component-mounted boards in the component mounting machine 2B.

[0084] Furthermore, as previously described, the replacement instruction list LB included in the replacement instruction data D2 contains information on the replacement sequence of feeders 25 corresponding to the faulty feeders 25A-25C and the parts-out feeders 25E and 25F. Therefore, the management system 5 outputs replacement instruction data D2 that instructs the replacement of feeders 25 according to the replacement sequence corresponding to the faulty feeders 25A-25C and the parts-out feeders 25E and 25F. According to the replacement instruction data D2 which includes such replacement instruction list LB, the feeders 25 can be replaced in the order corresponding to the faulty feeders 25A-25C and the parts-out feeders 25E and 25F. This makes it possible to replace the feeders 25 corresponding to the faulty feeders 25A-25C and to complete the replacement of the feeders 25 corresponding to the parts-out feeders 25E and 25F within the parts-out replacement allowable time OPT.

[0085] As previously described, the replacement order of feeders 25 in the replacement instruction list LB included in the replacement instruction data D2 is set based on the replacement priority according to the rank assigned to the faulty feeders 25A to 25C, in addition to the allowable replacement time OPT for the faulty feeders 25E and 25F. Therefore, the management system 5 outputs replacement instruction data D2 that instructs the replacement of feeders 25 according to the replacement priority based on the rank assigned to the faulty feeders 25A to 25C. In accordance with this replacement instruction data D2, the feeders 25 corresponding to the faulty feeders 25A to 25C can be replaced according to the replacement priority based on the rank of the faulty feeders 25A to 25C.

[0086] The management system 5 controls the exchange device 4 by outputting exchange instruction data D2 to the exchange device 4, and performs feeder placement processing S9 and exchange processing S10.

[0087] <Feeder placement process> In the feeder placement process S9, the management system 5 controls the exchange device 4 based on the exchange instruction list LB included in the exchange instruction data D2, thereby causing the feeders 25 to be replenished, which are stored in the storage unit 32 of the storage device 3, to be placed in the exchange unit 43 of the exchange device 4.

[0088] The feeder placement process S9 of the management system 5 will be explained with reference to Figure 13. In the storage unit 32 of the storage device 3, the feeders 25 to be replaced are placed according to the replacement order of the defective feeders 25A to 25C and the parts-out feeders 25E and 25F, which are to be recovered, based on the storage source information LB2 and the replenishment target information LB3 of the replacement instruction list LB. Specifically, in the storage unit 32, the feeder 25A to be replaced corresponding to the defective feeder 25A is supported by the storage support section 321a, the feeder 25E to be replaced corresponding to the parts-out feeder 25E is supported by the storage support section 321b, the feeder 25F to be replaced corresponding to the parts-out feeder 25F is supported by the storage support section 321c, the feeder 25B to be replaced corresponding to the defective feeder 25B is supported by the storage support section 321d, and the feeder 25C to be replaced corresponding to the defective feeder 25C is supported by the storage support section 321e.

[0089] Furthermore, in the replacement unit 43 of the replacement device 4, the replacement support section 431a is set as the collection destination for the feeder 25 to be recovered, with the parts supply unit 23 as the collection source, and the replacement support sections 431b to 431f are set as the supply source for the feeder 25 to be replenished, with the parts supply unit 23 as the replenishment destination.

[0090] In the feeder placement process S9, the management system 5 controls the exchange device 4 and moves the exchange device 4 so that the exchange unit 43 is positioned opposite the storage unit 32 of the storage device 3. With the exchange unit 43 positioned opposite the storage unit 32, the management system 5 moves the exchange unit 43 within the allowable movement range 432 so that the feeders 25A, 25E, 25F, 25B, and 25C to be replenished, supported by the storage support sections 321a to 321e of the storage unit 32, move and are positioned at the source exchange support sections 431b, 431c, 431d, 431e, and 431f of the exchange unit 43, and also operates the operating unit 42, including the arm section 44 and the hand section 45.

[0091] Specifically, the management system 5 performs a first positioning movement process to move the replacement unit 43 within the allowable movement range 432 so that the replacement support parts 431b, 431c, 431d, 431e, and 431f of the supply source face the storage support parts 321a to 321e that support the feeders 25A, 25E, 25F, 25B, and 25C to be replenished. Then, the management system 5 moves the arm part 44 so that the hand part 45 is positioned above the replacement support parts 431b, 431c, 431d, 431e, and 431f of the supply source, and then performs a second positioning movement process to move the hand part 45, which is gripping the feeders 25A, 25E, 25F, 25B, and 25C to be replenished, from the storage device 3 side to the replacement device 4 side. As a result, the feeders 25A, 25E, 25F, 25B, and 25C to be replenished are moved so as to be removed from the storage support sections 321a to 321e in the storage unit 32 and inserted into the replacement support sections 431b, 431c, 431d, 431e, and 431f of the source on the replacement unit 43.

[0092] As described above, the feeder placement process S9 of the management system 5 can cause the feeder 25 to be replenished, which is stored in the storage unit 32 of the storage device 3, to be placed in the exchange unit 43 of the exchange device 4.

[0093] <Exchange process> In the exchange unit 43 of the exchange device 4, when the exchange support section 431a, which will be the return destination for the feeder 25 to be recovered, is set, and the feeders 25A, 25E, 25F, 25B, and 25C to be replenished are placed in the exchange support sections 431b to 431f, the management system 5 performs an exchange process S10, which includes a recovery process S101 and a replenishment process S102. In the exchange process S10, the management system 5 controls the exchange device 4 based on the exchange instruction list LB included in the exchange instruction data D2, to recover the feeder 25 to be recovered that is mounted on the parts supply unit 23 to the exchange unit 43 of the exchange device 4, and in accordance with the recovery, replenishes the feeder 25 to be replenished that is placed in the exchange unit 43 to the parts supply unit 23.

[0094] The replacement process S10 of the management system 5 will be explained with reference to Figures 14 and 15. In the parts supply unit 23, the supply support sections 24a, 24b, 24c, 24e, and 24f, which are the source of the feeders 25 to be recovered and the destinations to which the feeders 25 to be replenished are replenished, support the defective feeders 25A to 25C and the parts-out feeders 25E and 25F, respectively.

[0095] In replacement process S10, the management system 5 controls the replacement device 4 and moves the replacement device 4 so that the replacement unit 43 is positioned opposite the component supply unit 23 of the component mounting machine 2B. With the replacement unit 43 positioned opposite the component supply unit 23, the management system 5 performs a recovery process S101 in which it moves the replacement unit 43, the arm unit 44 and the hand unit 45 so that the defective feeders 25A~25C and the component out-of-stock feeders 25E,25F, which are supported by the supply support units 24a, 24b, 24c, 24e, and 24f of the component supply unit 23, are moved and recovered by the replacement unit 43. Furthermore, the management system 5 performs a replenishment process S102 by moving the replacement unit 43, arm unit 44, and hand unit 45 so that the feeders to be replenished, 25A, 25E, 25F, 25B, and 25C, which are supported by the replacement support units 431b to 431f in the replacement unit 43, are moved and replenished to the supply support units 24a, 24b, 24c, 24e, and 24f, which are the replenishment destinations, after the defective feeders 25A to 25C and the parts-out feeders 25E and 25F have been removed from the parts supply unit 23. At this time, the management system 5 performs a recovery process S101 and a replenishment process S102 so that the feeders to be replenished, 25A, 25E, 25F, 25B, and 25C, are replenished to the parts supply unit 23 in accordance with the replacement order shown in the replacement instruction list LB, in response to the recovery of the defective feeders 25A to 25C and the parts-out feeders 25E and 25F.

[0096] Specifically, in the recovery process S101, the management system 5 performs a first recovery movement process and a second recovery movement process. In the first recovery movement process, the management system 5 moves the replacement unit 43 within the allowable movement range 432 so that the replacement support part 431a at the recovery destination faces the supply support part 24a at the recovery source that supports the first defective feeder 25A in the replacement sequence. Next, in the second recovery movement process, the management system 5 moves the arm part 44 so that the hand part 45 is positioned above the replacement support part 431a at the recovery destination. Then, the management system 5 moves the hand part 45, which is gripping the defective feeder 25A, from the component mounting machine 2B side to the replacement device 4 side. As a result, the defective feeder 25A is moved so that it is pulled out from the supply support part 24a at the recovery source within the component supply unit 23 and recovered at the replacement support part 431a at the recovery destination on the replacement unit 43.

[0097] When the faulty feeder 25A is retrieved to the replacement support unit 431a at the retrieval destination, the management system 5 performs replenishment processing S102. In replenishment processing S102, the management system 5 performs a first replenishment movement process and a second replenishment movement process. In the first replenishment movement process, the management system 5 moves the replacement unit 43 within the allowable movement range 432 so that the replacement support unit 431b at the replenishment source, which supports the feeder 25A that is the first to be replaced, faces the supply support unit 24a at the replenishment destination. Next, in the second replenishment movement process, the management system 5 moves the arm unit 44 so that the hand unit 45 is positioned above the replacement support unit 431b at the replenishment source. Then, the management system 5 moves the hand unit 45, which is gripping the feeder 25A to be replaced, from the replacement device 4 side to the component mounting machine 2B side. As a result, the feeder 25A to be replenished is moved so as to be withdrawn from the replacement support section 431b of the supply source on the replacement unit 43, and is replenished to the supply support section 24a of the supply destination within the parts supply unit 23.

[0098] When the feeder 25A to be replenished is supplied to the supply support unit 24a, the replacement support unit 431b in the replacement unit 43 becomes empty, no longer supporting the feeder 25. In this case, the management system 5 uses the now empty replacement support unit 431b as the recovery destination and performs recovery process S101 for the second component-depleted feeder 25E in the replacement sequence. As a result, the component-depleted feeder 25E moves so as to be pulled out from the source supply support unit 24e in the parts supply unit 23 and is recovered to the empty replacement support unit 431b on the replacement unit 43, which is the recovery destination. Once the component-depleted feeder 25E is recovered to the replacement support unit 431b, the management system 5 performs recovery process S102 for the second component-depleted feeder 25E in the replacement sequence. As a result, the feeder 25E moves so as to be pulled out from the source replacement support unit 431c on the replacement unit 43 and is supplied to the destination supply support unit 24e in the parts supply unit 23.

[0099] Similarly, the management system 5 performs the recovery process S101 and replenishment process S102 for the third and subsequent replacements in the exchange sequence.

[0100] As described above, the replacement process S10, which includes the recovery process S101 and replenishment process S102 of the management system 5, recovers the defective feeders 25A to 25C and the depleted parts feeders 25E and 25F attached to the parts supply unit 23 to the replacement unit 43 of the replacement device 4. In accordance with this recovery, the feeders 25 to be replenished, which are located in the replacement unit 43, can be supplied to the parts supply unit 23.

[0101] By replenishing the feeders 25A to 25C that are subject to replenishment in response to the recovery of the defective feeders 25A to 25C, it is possible to improve the poor state of component adsorption by the adsorption nozzle 261 caused by the defective feeders 25A to 25C. This makes it possible to improve the productivity of component-mounted boards in the component mounting machine 2B and to improve the quality of the component-mounted boards. Furthermore, by replenishing the feeders 25E and 25F that are subject to replenishment in response to the recovery of the component-depleted feeders 25E and 25F, it is possible to avoid the interruption of component supply caused by component-depleted feeders 25E and 25F, thereby enabling the continuation of component-mounted board production in the component mounting machine 2B.

[0102] The specific embodiments described above mainly include inventions having the following configurations.

[0103] A component mounting system according to one aspect of the present invention includes a component supply unit equipped with a plurality of feeders for supplying components, a head unit having a plurality of suction nozzles for picking up components supplied by the plurality of feeders and mounting the picked-up components onto a substrate, a component mounting machine for producing component-mounted substrates on which components are mounted, and a management system for managing the production of the component-mounted substrates. The management system performs the following: a production process that controls the plurality of feeders and the head unit to produce the component-mounted substrates in the component mounting machine; a defect rate recognition process that recognizes the defect rate for each of the plurality of feeders regarding the defect rate of the component adsorption state by the plurality of suction nozzles, based on production status data indicating the production status of the component-mounted substrates in the component mounting machine; a recovery target identification process that extracts a defect-causing feeder that is the cause of the defect in the component adsorption state by the plurality of suction nozzles from among the high-defect-rate feeders whose feeder-specific defect rate exceeds a predetermined threshold, and identifies the defect-causing feeder as a feeder to be recovered from the component supply unit; and a replacement instruction process that outputs replacement instruction data indicating an instruction to replace a feeder to supply a feeder to the component supply unit in response to the recovery of the feeder to be recovered.

[0104] According to this component mounting system, the management system identifies a faulty feeder among the multiple feeders attached to the component supply unit of the component mounting machine that is causing poor component suction by multiple suction nozzles, and designates it as a feeder to be recovered from the component supply unit. The management system then recovers the faulty feeder from the component supply unit and outputs replacement instruction data indicating that a replacement feeder should be supplied to the component supply unit in response to the recovery. By replenishing the replacement feeder in response to the recovery of the faulty feeder from the component supply unit according to the replacement instruction data, it is possible to improve the poor component suction caused by the faulty feeder. This makes it possible to improve the productivity of component-mounted substrates in the component mounting machine and to enhance the quality of the component-mounted substrates.

[0105] In the component mounting system described above, the management system may, in the defect rate recognition process, recognize, based on the production status data, the nozzle-specific defect rate, which indicates the defect rate of the component adsorption state by the plurality of adsorption nozzles for each of the plurality of adsorption nozzles, along with the feeder-specific defect rate, and in the recovery target identification process, extract the defect-causing feeder from the high-defect-rate feeders based on the feeder-specific defect rate and the nozzle-specific defect rate.

[0106] In this embodiment, the management system extracts the feeders causing defects from among the high-defect rate feeders based on the feeder-specific defect rate and the nozzle-specific defect rate. This allows the management system to accurately extract the feeders causing defects from among the high-defect rate feeders.

[0107] In the component mounting system described above, the management system may perform a mounting accuracy recognition process as a preprocessing step before the recall target identification process, in which it recognizes a mounting accuracy index value for each of the multiple feeders, which is an indicator of the mounting accuracy of components on the component mounting substrate, based on the production status data. In this case, the management system assigns a rank to the defective feeder according to the mounting accuracy index value during the recall target identification process.

[0108] In this embodiment, the management system assigns a rank to the defective feeder according to the mounting accuracy index value. This allows the defective feeder to be ranked according to the mounting accuracy of the components on the component mounting board based on the mounting accuracy index value.

[0109] In the component mounting system described above, the management system may perform a priority setting process as a preprocessing step before the replacement instruction process, which sets the priority for replacing the feeder corresponding to the defective feeder based on the rank assigned to the defective feeder. In this case, the management system outputs the replacement instruction data instructing the replacement of the feeder according to the priority during the replacement instruction process.

[0110] In this embodiment, the management system sets a priority for replacing defective feeders based on the rank assigned to each feeder, and outputs replacement instruction data that instructs the replacement of the feeder according to that priority. In accordance with this replacement instruction data, the system can replace the feeder corresponding to the defective feeder according to the replacement priority based on the rank of the defective feeder.

[0111] The above-described component mounting system may further include a replacement device having a storage unit installed in a preparation area adjacent to the production area where the component mounting machine is installed, for storing the feeders to be replenished; a replacement unit that is movable within the production area to positions opposite the component supply unit and the storage unit of the component mounting machine, respectively, and supports the feeders to be exchanged with the component supply unit; and an operation unit that performs the operation of moving the feeders relative to the replacement unit. In this case, the management system controls the replacement device by outputting the replacement instruction data to the replacement device during the replacement instruction processing. The management system then performs a feeder placement process, in which the operating unit is operated so that the feeders to be replenished, stored in the storage unit, move to a position opposite the storage unit and are placed in the exchange unit, and an exchange process, in which the operating unit is operated so that the feeders to be recovered, mounted on the parts supply unit, move to a position opposite the parts supply unit and are recovered into the exchange unit, and the feeders to be replenished, placed in the exchange unit, move to the parts supply unit and are replenished into the parts supply unit.

[0112] In this embodiment, the management system controls the exchange device by outputting exchange instruction data to the exchange device, and performs feeder placement processing and exchange processing. The feeder placement processing of the management system causes the feeders to be replenished, which are stored in the storage unit, to be placed in the exchange unit of the exchange device. Then, the exchange processing of the management system retrieves the feeders to be recovered, which are attached to the parts supply unit, into the exchange unit of the exchange device, and in accordance with the recovery, the feeders to be replenished, which are placed in the exchange unit, can be supplied to the parts supply unit.

[0113] In the component mounting system described above, the management system may perform a preparation instruction process that outputs preparation instruction data indicating an instruction to prepare the feeder to be replenished so that the feeder to be replenished is stored in the storage unit.

[0114] In this embodiment, the feeder to be replenished is prepared according to the preparation instruction data, and then stored in the storage unit.

[0115] In the component mounting system described above, the management system may perform a component shortage recognition process as a preprocessing step before the recall target identification process, in which it recognizes a component shortage index value for each of the plurality of feeders, which serves as an indicator for predicting component shortages, based on the production status data. In this case, in the recall target identification process, the management system extracts component shortage feeders from the plurality of feeders that are predicted to be out of parts based on the component shortage index value, and identifies the component shortage feeders together with the faulty feeders as feeders to be recalled. The management system then calculates a component shortage replacement allowance time, which indicates the time allowed for the replacement of the feeder corresponding to the component shortage feeder, based on the component shortage index value, and performs a replacement order setting process as a preprocessing step before the replacement instruction process, in which it sets the replacement order of the faulty feeders and the feeders corresponding to the component shortage feeders so that the replacement of the feeder corresponding to the component shortage feeder by the replacement device is completed within the component shortage replacement allowance time. In this case, in the replacement instruction process, the management system outputs the replacement instruction data to the replacement device instructing the replacement of the feeders according to the replacement order.

[0116] In this embodiment, the management system extracts feeders that are predicted to run out of parts from among multiple feeders installed in the parts supply unit based on the parts shortage index value, and identifies these feeders as feeders to be recovered from the parts supply unit. In this case, the management system sets the replacement order of feeders corresponding to the faulty feeder and the parts shortage feeder so that the replacement of the feeder corresponding to the parts shortage feeder by the replacement device is completed within the parts shortage replacement allowable time. The management system then outputs replacement instruction data instructing the replacement of feeders according to the set replacement order. According to this replacement instruction data, the feeders can be replaced in the order corresponding to the faulty feeder and the parts shortage feeder. This makes it possible to replace the feeder corresponding to the faulty feeder and to complete the replacement of the feeder corresponding to the parts shortage feeder within the parts shortage replacement allowable time.

[0117] In the component mounting system described above, the replacement unit of the replacement device has a plurality of replacement support parts arranged in a predetermined direction as support parts for the feeder, and may be movable in the direction of the arrangement of the plurality of replacement support parts. In this case, the management system moves the replacement unit and operates the operating unit when the replacement device replaces the feeder corresponding to the faulty feeder and the feeder with no parts in the replacement process. The management system then sets the replacement order in the replacement order setting process so that the amount of movement of the replacement unit in the replacement process falls within a predetermined target range.

[0118] In this embodiment, the management system sets the replacement sequence for feeders corresponding to faulty feeders and parts-out feeders so that the amount of movement of the replacement unit of the replacement device during the replacement process falls within a predetermined target range. This improves the efficiency of feeder replacement by the replacement device for parts supply units during the replacement process.

[0119] In the component mounting system described above, if a replacement feeder capable of supplying the same type of component as the feeder to be recovered is installed in the component supply unit, the management system may, in the production process, supply components from the replacement feeder until the replacement of the feeder corresponding to the feeder to be recovered is completed.

[0120] In this embodiment, while the feeder to be recovered is recovered from the parts supply unit and the feeder to be replenished in response to the recovery is being supplied to the parts supply unit, the management system causes the parts to be supplied from the substitute feeder. This allows the supply of parts from the substitute feeder to continue while the feeder replacement is being carried out in the parts supply unit.

[0121] In the component mounting system described above, if a simultaneous adsorption group is set for each component supplied by the plurality of feeders, indicating a group of at least two components that are simultaneously adsorbed by the plurality of adsorption nozzles, the management system may perform a productivity recognition process to recognize a productivity index value, which is an indicator of the productivity of the component mounting substrate in the component mounting machine, based on the production status data. In this case, if the productivity index value falls below a predetermined standard value, the management system performs a re-mounting instruction process, which outputs re-mounting instruction data indicating an instruction to re-mount the component supply unit of the simultaneous adsorption feeder that supplies components belonging to the simultaneous adsorption group in the plurality of feeders.

[0122] In this embodiment, a simultaneous suction group is set for each component supplied by multiple feeders attached to the component supply unit. Accordingly, a simultaneous suction feeder is set in each of the multiple feeders to supply the components belonging to the simultaneous suction group. In this case, during the production process, the management system simultaneously picks up each component belonging to the simultaneous suction group supplied by the simultaneous suction feeder using multiple suction nozzles. This improves the efficiency of the component picking operation of each suction nozzle in the head unit, thereby improving the productivity of component-mounted substrates in the component mounting machine.

[0123] On the other hand, if the productivity index value, which is an indicator of the productivity of component-mounted substrates in a component mounting machine, falls below a predetermined standard value, it is assumed that the supply status of each component picked up simultaneously by multiple suction nozzles by the simultaneous suction feeder is defective, for example, that the component is not supplied to the correct position or that the orientation of the component is not correct. Therefore, if the productivity index value falls below the predetermined standard value, the management system performs a reattachment instruction process, which outputs reattachment instruction data indicating an instruction to reattach the simultaneous suction feeder to the component supply unit. By reattaching the simultaneous suction feeder to the component supply unit according to the reattachment instruction data, it is possible to improve the supply status of components by the simultaneous suction feeder. When the supply status of components by the simultaneous suction feeder is improved, the productivity index value will not fall below the predetermined standard value, and the productivity of component-mounted substrates in the component mounting machine will improve.

[0124] In the component mounting system described above, if the productivity index value falls below a predetermined standard value after the re-mounting instruction processing, the management system may perform simultaneous adsorption response instruction processing, which outputs simultaneous adsorption response instruction data indicating an instruction to retrieve the simultaneous adsorption feeder from the component supply unit and to supply a new feeder to the component supply unit in accordance with the retrieval.

[0125] If, after processing the re-installation instruction, the productivity index value still falls below a predetermined standard value, it is assumed that the supply status of components by the simultaneous suction feeder has not improved even if the simultaneous suction feeder is re-installed on the component supply unit. Therefore, if the productivity index value falls below a predetermined standard value after processing the re-installation instruction, the management system performs simultaneous suction response instruction processing. In simultaneous suction response instruction processing, the management system outputs simultaneous suction response instruction data indicating that it will retrieve the simultaneous suction feeder from the component supply unit and supply a new feeder to the component supply unit in response to its retrieval. By supplying a new feeder in response to the retrieval of the simultaneous suction feeder from the component supply unit according to the simultaneous suction response instruction data, it is possible to eliminate the failure of simultaneous suction by multiple suction nozzles caused by the poor component supply status of the simultaneous suction feeder. As a result, the productivity index value does not fall below a predetermined standard value, and the productivity of component-mounted substrates in the component mounting machine is improved.

[0126] In the component mounting system described above, the management system may, if there is a non-supplying feeder among the plurality of feeders that has output error information indicating that it is unable to supply components, perform a non-supplying response instruction process that retrieves the non-supplying feeder from the component supply unit and outputs non-supplying response instruction data indicating an instruction to supply a new feeder to the component supply unit in response to the retrieval.

[0127] In this embodiment, if there is a non-supplying feeder that has output error information among the multiple feeders installed in the parts supply unit, the management system performs a non-supplying response instruction process. In the non-supplying response instruction process, the management system outputs non-supplying response instruction data indicating that it will retrieve the non-supplying feeder from the parts supply unit and supply a new feeder to the parts supply unit in response to its retrieval. By supplying a new feeder in response to the retrieval of the non-supplying feeder from the parts supply unit in accordance with the non-supplying response instruction data, it is possible to resolve the non-supplying state of parts caused by the non-supplying feeder.

[0128] In the component mounting system described above, the management system may perform maintenance response instruction processing if there is a feeder among the plurality of feeders that is subject to maintenance, retrieve the feeder subject to maintenance from the component supply unit, and output maintenance response instruction data indicating an instruction to supply a new feeder to the component supply unit in response to the retrieval.

[0129] In this embodiment, if there is a feeder to be maintained among the multiple feeders attached to the parts supply unit, the management system performs maintenance response instruction processing. In the maintenance response instruction processing, the management system outputs maintenance response instruction data indicating an instruction to retrieve the feeder to be maintained from the parts supply unit and to replenish the parts supply unit 23 with a new feeder in response to its retrieval. By supplying a new feeder in response to the retrieval of the feeder to be maintained from the parts supply unit in accordance with the maintenance response instruction data, it is possible to resolve the situation in which parts cannot be supplied due to feeder maintenance.

[0130] As described above, the present invention provides a component mounting system that can improve the productivity of component-mounted substrates in a component mounting machine and enhance the quality of component-mounted substrates.

Claims

1. A component mounting machine that produces component-mounted substrates, including a component supply unit equipped with multiple feeders for supplying components, and a head unit having multiple suction nozzles for picking up components supplied by the multiple feeders and mounting the picked-up components onto a substrate, A storage unit is installed in a preparation area adjacent to the production area where the component mounting machine is installed, and stores the feeders to be replenished. A replacement device comprising: a replacement unit that is movable within the production area to positions opposite the component supply unit and the storage unit of the component mounting machine, respectively, and which supports a feeder to be exchanged with the component supply unit; and an operation unit that performs an operation to move the feeder relative to the replacement unit; The system includes a management system for managing the production of the aforementioned component-mounted circuit boards, The aforementioned management system is A production process that controls the plurality of feeders and the head unit to produce the component mounting board in the component mounting machine, Based on production status data indicating the production status of the component-mounted substrate in the component mounting machine, a defect rate recognition process recognizes the feeder-specific defect rate for each of the multiple feeders, which indicates the defect rate of the component adsorption state by the multiple adsorption nozzles. A parts shortage recognition process that recognizes a parts shortage index value for each of the multiple feeders, which serves as an indicator for predicting parts shortages, based on the aforementioned production status data, From among the multiple feeders, the feeder-specific defect rate feeders exceeding a predetermined threshold are selected as high-defect rate feeders that cause defects in the adsorption state of parts by the multiple adsorption nozzles, and based on the part shortage index value, the feeders from which part shortages are predicted are selected as part shortage feeders, and the defective feeders and the part shortage feeders are identified as feeders to be recovered from the parts supply unit in a recovery target identification process. A replacement instruction process controls the replacement device by outputting replacement instruction data to the replacement device indicating an instruction to replace a feeder in order to replenish a feeder to the parts supply unit in response to the recovery of the feeder to be recovered, With the exchange device moved to a position opposite the storage unit, the feeder placement process involves operating the operating unit so that the feeders to be replenished, which are stored in the storage unit, are moved and placed in the exchange unit. With the replacement device moved to a position opposite the parts supply unit, the replacement process is performed by operating the operating unit such that the feeder to be recovered, which is attached to the parts supply unit, moves and is recovered into the replacement unit, and the feeder to be replenished, which is located in the replacement unit, moves and is replenished into the parts supply unit. A component failure replacement allowance time, which indicates the time allowed for replacing the feeder corresponding to the component failure feeder, is calculated based on the component failure index value, and a replacement order setting process is performed as a preprocessing step for the replacement instruction process to set the replacement order of the faulty feeder and the feeder corresponding to the component failure so that the replacement of the feeder corresponding to the component failure feeder by the replacement device is completed within the component failure replacement allowance time. A component mounting system that, in the replacement instruction processing, outputs replacement instruction data to the replacement device instructing the replacement of feeders according to the replacement order.

2. The aforementioned management system is In the defect rate recognition process, based on the production status data, the defect rate of the part adsorption state by the plurality of adsorption nozzles is recognized, along with the feeder-specific defect rate, which is shown for each of the plurality of adsorption nozzles. The component mounting system according to claim 1, wherein in the process for identifying items to be recovered, the component causing the defect is extracted from the high-defect rate feeders based on the feeder-specific defect rate and the nozzle-specific defect rate.

3. The aforementioned management system is Based on the production status data, a mounting accuracy recognition process is performed as a preprocessing step for the recall target identification process to recognize a mounting accuracy index value for each of the multiple feeders, which serves as an indicator of the mounting accuracy of components on the component mounting substrate. The component mounting system according to claim 1, wherein in the recall target identification process, a rank is assigned to the defective feeder according to the mounting accuracy index value.

4. The aforementioned management system is As a preprocessing step before the replacement instruction process, a priority setting process is performed to set the priority for replacing the feeder corresponding to the faulty feeder, based on the rank assigned to the faulty feeder. The component mounting system according to claim 3, wherein the replacement instruction process outputs replacement instruction data that instructs the replacement of the feeder according to the priority.

5. The component mounting system according to claim 1, wherein the management system performs a preparation instruction process that outputs preparation instruction data indicating an instruction to prepare the feeder to be replenished so that the feeder to be replenished is stored in the storage unit.

6. The exchange unit of the exchange device has a plurality of exchange support parts arranged in a predetermined direction as support parts for the feeder, and is movable in the direction of the arrangement of the plurality of exchange support parts. The aforementioned management system is In the replacement process, when the replacement device replaces the feeder corresponding to the faulty feeder and the feeder with missing parts, the replacement unit is moved and the operating unit is operated. The component mounting system according to claim 1, wherein in the exchange sequence setting process, the exchange sequence is set such that the amount of movement of the exchange unit in the exchange process falls within a predetermined target range.

7. The component mounting system according to claim 1, wherein, if a replacement feeder capable of supplying the same type of component as the feeder to be recovered is installed in the component supply unit, the management system causes the production process to supply components from the replacement feeder until the replacement of the feeder corresponding to the feeder to be recovered is completed.

8. A component mounting machine that produces component-mounted substrates, including a component supply unit equipped with multiple feeders for supplying components, and a head unit having multiple suction nozzles for picking up components supplied by the multiple feeders and mounting the picked-up components onto a substrate, The system includes a management system for managing the production of the aforementioned component-mounted circuit boards, The aforementioned management system is A production process that controls the plurality of feeders and the head unit to produce the component mounting board in the component mounting machine, Based on production status data indicating the production status of the component-mounted substrate in the component mounting machine, a defect rate recognition process recognizes the feeder-specific defect rate for each of the multiple feeders, which indicates the defect rate of the component adsorption state by the multiple adsorption nozzles. From among the feeders with a high failure rate, the failure rate of each feeder exceeds a predetermined threshold, and a failure-causing feeder that is the cause of poor suction of parts by the multiple suction nozzles is extracted, and the failure-causing feeder is identified as a feeder to be recovered from the parts supply unit; The process involves outputting replacement instruction data indicating an instruction to replace a feeder in response to the recovery of the feeder to be recovered, and supplying the feeder to be replenished to the parts supply unit. If a simultaneous adsorption group is set for each component supplied by the plurality of feeders, indicating a group of at least two components that are simultaneously adsorbed by the plurality of adsorption nozzles, then a productivity recognition process is performed to recognize a productivity index value that serves as an indicator of the productivity of the component mounting substrate in the component mounting machine, based on the production status data. A component mounting system that, when the productivity index value falls below a predetermined standard value, performs a re-mounting instruction process that outputs re-mounting instruction data indicating an instruction to re-mount the component supply unit of the simultaneous adsorption feeder that supplies components belonging to the simultaneous adsorption group in the plurality of feeders.

9. The component mounting system according to claim 8, wherein the management system, after processing the re-mounting instruction process, performs a simultaneous adsorption response instruction process to retrieve the simultaneous adsorption feeder from the component supply unit and output simultaneous adsorption response instruction data indicating an instruction to replenish the component supply unit with a new feeder in accordance with the retrieval, if the productivity index value falls below the predetermined reference value.

10. The component mounting system according to claim 1, wherein the management system, if there is a non-supplying feeder among the plurality of feeders that has output error information indicating that it is unable to supply components, retrieves the non-supplying feeder from the component supply unit and outputs non-supplying response instruction data indicating an instruction to supply a new feeder to the component supply unit in response to the retrieval.

11. The component mounting system according to claim 1, wherein the management system, when there is a feeder among the plurality of feeders that is subject to maintenance, retrieves the feeder subject to maintenance from the component supply unit and outputs maintenance response instruction data indicating an instruction to supply a new feeder to the component supply unit in accordance with the retrieval.

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