Production planning apparatus and production planning method

Abstract

To provide a production plan creation apparatus and a production plan creation method that can recreate a production plan so that production can be continued even on a production line where production facilities or apparatus resources are out of order.SOLUTION: A production plan creation method for creating a production plan of a production device, includes: obtaining failure information including a failure location of a production device which produces products based on an original production plan including a production order of a plurality of kinds of products (ST11); determining new production order by changing a production order of at least a kind of product being produced and remaining kinds of products out of the plurality kinds of products based on the failure information (ST24); and creating a new production plan based on the new production order (ST25).SELECTED DRAWING: Figure 8

Description

[[Technical Field]]

[0001] The present invention relates to a production plan creation apparatus and a production plan creation method for creating a production plan for a production apparatus. [[Background Art]]

[0002] In a production line provided with production apparatuses such as component mounting apparatuses, products such as mounted boards of a plurality of types are produced while changing apparatus resources such as feeders and nozzles attached to the production apparatuses. If a production apparatus or an apparatus resource breaks down while a product is being produced on the production line, the production of the product on that production line is interrupted. Patent Document 1 discloses a production management apparatus that creates a recovery plan in which, when production of a product is interrupted due to a breakdown of a production apparatus or an apparatus resource, production is resumed after waiting for repair of the production apparatus or the apparatus resource, or the product type is alternatively produced on another production line. [[Prior Art Documents]] [[Patent Documents]]

[0003] [[Patent Document 1]] International Publication No. 2018 / 079778 [[Summary of the Invention]] [[Problem to be Solved by the Invention]]

[0004] However, in the conventional techniques including Patent Document 1, when waiting for repair of a production apparatus or an apparatus resource, a loss occurs due to the stoppage of production. Further, when alternative production is performed on another production line, there has been a problem that work of removing the apparatus resource from the production line whose production has been stopped and reattaching it to another production line is required, which imposes a great burden on an operator.

[0005] Accordingly, an object of the present invention is to provide a production plan creation apparatus and a production plan creation method capable of recreating a production plan so that production can be continued even on a production line in which production equipment or an apparatus resource has broken down. [Means for solving the problem]

[0006] The production planning device of the present invention is a production planning device that creates a production plan for a production device, comprising: an acquisition unit that acquires fault information including fault locations of a production device that is producing products based on an original production plan that includes the production order of multiple types of products; a production order modification unit that, based on the fault information, changes the production order of at least the type of product that was being produced and the remaining types of products to determine a new production order; and a production plan modification unit that creates a new production plan based on the new production order. The production sequence change unit determines the new production sequence such that the remaining production of the previously produced type of product follows the production of the type of product that does not use the equipment resources at the faulty location, and the production plan change unit creates a new production plan in which the production equipment produces the type of product that does not use the equipment resources at the faulty location until the repair of the equipment resources at the faulty location is completed. ru.

[0007] The present invention relates to a production planning method for creating a production plan for a production apparatus, comprising: an acquisition step of acquiring fault information including fault locations of a production apparatus that is producing products based on an original production plan that includes the production order of multiple types of products; a production order modification step of changing the production order of at least the type of product that was being produced and the remaining types of products among the multiple types of products based on the fault information to determine a new production order; and a production plan modification step of creating a new production plan based on the new production order. The production sequence change step determines the new production sequence such that the remaining production of the previously produced type of product follows the production of the type of product that does not use the equipment resources at the faulty location, and the production plan change step creates the new production plan which produces the type of product that does not use the equipment resources at the faulty location in the production equipment until the repair of the equipment resources at the faulty location is completed. . [Effects of the Invention]

[0008] According to the present invention, it is possible to recreate a production plan so that production can continue even on a production line where production equipment or device resources have failed. [Brief explanation of the drawing]

[0009] [Figure 1] Diagram illustrating the configuration of a component mounting system according to one embodiment of the present invention. [Figure 2] Block diagram showing the configuration of the information processing system of a management computer (production planning device) according to one embodiment of the present invention. [Figure 3] An explanatory diagram illustrating an example of a production plan used in a management computer (production plan creation device) according to one embodiment of the present invention. [Figure 4]An explanatory diagram illustrating an example of similarity information used in a management computer (production planning device) according to one embodiment of the present invention. [Figure 5] This is an explanatory diagram illustrating an example of a corresponding selection screen displayed on the display unit of a management computer (production planning device) according to one embodiment of the present invention. [Figure 6] (a) Explanatory diagram of an example of the original production plan in a component mounting line according to one embodiment of the present invention (b) Explanatory diagram of an example of a newly created modified production plan [Figure 7] Flowchart of a production plan creation method according to one embodiment of the present invention [Figure 8] Flowchart of a method for creating a modified production plan according to one embodiment of the present invention [Figure 9] Flowchart of another embodiment of the production plan creation method according to one embodiment of the present invention. [Modes for carrying out the invention]

[0010] An embodiment of the present invention will be described in detail below with reference to the drawings. The configurations, shapes, etc. described below are illustrative examples for illustrative purposes and can be modified as appropriate according to the specifications of the component mounting system, management computer, component mounting line, printing device, component mounting device, etc. In the following, all corresponding elements are denoted by the same reference numerals in all drawings, and redundant explanations are omitted.

[0011] First, with reference to Figure 1, the configuration of the component mounting system 1 will be explained. The component mounting system is configured such that production equipment constituting a single component mounting line L is connected by a communication network 2 and managed by a management computer 3. The component mounting line L is configured by connecting production equipment such as a substrate supply device M1, a printing device M2, a printing inspection device M3, component mounting devices M4-M8, a mounting inspection device M9, a reflow device M10, and a substrate recovery device M11 in series from upstream (left side of the page) to downstream (right side of the page) in the substrate transport direction. The component mounting line L has the function of producing mounted substrates with components mounted on them. Note that the component mounting line L is a group of production equipment connected via the communication network 2, and the production equipment does not need to be physically connected to each other.

[0012] In Figure 1, the substrate supply device M1 is equipped with a storage section such as a rack for storing multiple substrates, and performs the substrate supply operation by supplying substrates taken from the storage section to downstream equipment. The printing device M2 is a production device that performs the solder printing operation by printing paste-like solder onto substrates transported from upstream via a screen mask mounted on the printing work section. The printing device M2 prints solder onto the substrate by bringing the substrate into contact with a screen mask having multiple openings, and moving a squeegee in contact with the screen mask to push the solder supplied onto the screen mask into the openings. The printing device M2 is equipped with a cleaning section that periodically removes solder adhering to the surface of the screen mask that contacts the substrate.

[0013] The printing inspection device M3 is a production device that performs printing inspection work, inspecting the condition of the solder printed on the substrate using a printing inspection work unit that includes a solder inspection camera and various sensors. The monitoring results, including error information such as printing errors detected from the surface condition of the solder-deposited substrate inspected by the printing inspection device M3, are transmitted to the management computer 3.

[0014] In Figure 1, component mounting devices M4 to M8 are production devices that perform component mounting work by picking up components supplied by component supply devices such as tape feeders and tray feeders using nozzles mounted on mounting heads and mounting them onto circuit boards with solder printed on them. A tape feeder is a component supply device that supplies components by feeding a carrier tape that holds the components. A tray feeder is a component supply device that supplies components by changing trays that hold multiple components. Component mounting devices M4 to M8 are equipped with component recognition cameras that image the components held by the nozzles, sensors that measure the flow rate of air flowing into the nozzles, and head cameras that image the components supplied by the component supply devices.

[0015] The component mounting apparatuses M4 to M8 use a camera and various sensors during component mounting work to monitor errors including mounting errors caused by a mounting head, suction errors in which a nozzle does not normally suck a component, and supply errors in which a component supply device does not normally supply a component. Monitoring results including error information of such errors as mounting errors, suction errors, and supply errors are transmitted to the management computer 3. It should be noted that the component mounting line L is not limited to a configuration including five component mounting apparatuses M4 to M8, and may include one to four component mounting apparatuses M4 to M8, or six or more thereof.

[0016] In FIG. 1, the mounting inspection apparatus M9 is a production apparatus that performs mounting inspection work of inspecting the state of components mounted on a substrate by a mounting inspection working unit including a mounting inspection camera. Monitoring results including error information such as mounting errors where a component is not mounted at a predetermined position on a substrate inspected by the mounting inspection apparatus M9 are transmitted to the management computer 3. The reflow apparatus M10 heats a substrate carried into the apparatus by a substrate heating unit, cures the solder on the substrate, and performs a substrate heating work of joining the electrode portions of the substrate and the components. The substrate recovery apparatus M11 includes a storage unit such as a rack that stores a plurality of substrates, and performs a substrate recovery work of receiving substrates carried out by an upstream apparatus and recovering the substrates into the storage unit.

[0017] In FIG. 1, the management computer 3 has a function of creating data and parameters required for operating production apparatuses provided in the component mounting line L and transmitting the data and parameters to each production apparatus. In addition, the management computer 3 collects monitoring results including error information of production apparatuses from a plurality of production apparatuses provided in the component mounting line L. Further, when the management computer 3 determines that an apparatus resource mounted on a production apparatus has failed based on the collected information, the management computer 3 has a function of creating a new production plan that allows continuing production of mounted substrates. It should be noted that the component mounting system 1 does not need to include one component mounting line L, and may include two or more component mounting lines L. A preparation room PA is installed in the floor where the component mounting line L is installed. In the preparation room PA, in addition to storing materials and apparatus resources used for production, preparation for production and maintenance and repair of apparatus resources are performed.

[0018] As described above, the printing apparatus M2 is a production apparatus that is equipped with apparatus resources such as a screen mask and a squeegee and performs solder printing work. Failures such as damage to the screen mask and clogging of openings that cannot be removed by regular cleaning work performed by an internal cleaning unit are identified from the state of solder printed on a substrate inspected by the print inspection apparatus M3 (such as solder blurring or bleeding).

[0019] The component mounting apparatuses M4 to M8 are production apparatuses that are equipped with apparatus resources such as a mounting head, a nozzle, a tape feeder, and a tray feeder, and perform component mounting work. Failures of the mounting head, nozzle, tape feeder, and tray feeder (apparatus resources) are detected by various sensors built into the component mounting apparatuses M4 to M8. In addition, failures of the mounting head, nozzle, tape feeder, and tray feeder are identified from error information detected by the component mounting apparatuses M4 to M8 (such as mounting errors, suction errors, and supply errors) and the state of components mounted on the substrate inspected by the mounting inspection apparatus M9 (such as mounting errors). Note that a failure may be identified when signals from the mounting head, tape feeder, and tray feeder can no longer be acquired.

[0020] Next, the configuration of the information processing system of the management computer 3 will be described with reference to FIG. 2. Here, among the plurality of functions provided by the management computer 3, the function as a production plan creation apparatus that creates a new production plan capable of continuing production on the production line when an apparatus resource (a screen mask, mounting head, nozzle, tape feeder, tray feeder, etc.) of a production apparatus (the printing apparatus M2, component mounting apparatuses M4 to M8, etc.) fails while the production line (component mounting line L) is producing a product (mounted substrate) will be described.

[0021] The management computer 3 includes a processing unit 10, a storage unit 19, as well as an input unit 28, a display unit 29, and a communication unit 30. The processing unit 10 is a data processing device such as a CPU, and its internal processing units include a receiving unit 11, a choice presentation unit 12, a failure information creation unit 13, an acquisition unit 14, a similarity calculation unit 15, a model changeover time calculation unit 16, a production sequence change unit 17, and a production plan change unit 18. The management computer 3 does not need to be composed of a single computer, but may be composed of multiple devices. For example, all or part of the storage unit and processing unit may be stored in the cloud.

[0022] In Figure 2, the input unit 28 is an input device such as a keyboard, touch panel, or mouse, and is used for inputting operation commands and data. The display unit 29 is a display device such as a liquid crystal panel, which displays various data stored in the storage unit 19, as well as various information such as operation screens and input screens for operations performed by the input unit 28. The communication unit 30 is a communication interface that transmits and receives data between the production equipment (printing device M2, printing inspection device M3, component mounting devices M4-M8, mounting inspection device M9, etc.) that make up the component mounting line L via the communication network 2.

[0023] The memory unit 19 stores production plans 20, error information 21, failure information 22, equipment resource information 23, predicted repair time information 24, standard changeover time information 25, similarity information 26, and modified production plans 27. The production plan 20 includes information that identifies the type of mounted board (product) for each lot of mounted boards (products) to be produced on the component mounting line L, as well as information such as production sequence, production quantity, predicted production time, predicted setup time, and production delivery date. The production plan 20 also includes a correspondence list that identifies the equipment resources to be placed in the production equipment for each type of mounted board (or each lot) and their placement. In other words, the correspondence list shows the correspondence (placement) between the type of mounted board (product) and the equipment resources of the production equipment used to produce the mounted board (product).

[0024] Here, with reference to Figure 3, an example of production plan 20 will be explained. Here, a production plan 20 for one shift scheduled for component mounting line L is shown. Production plan 20 includes the production sequence 31 for each lot number 32, the product type number 33 that identifies the type of mounted board, the number of boards to be produced 34, the predicted production time 35, the predicted changeover time 36, and the production deadline 37. In this example, production of five lots is planned for component mounting line L. The first lot scheduled for production (sequence 31 is "1"), with lot number 32 "A" (hereinafter referred to as "Lot A," etc.), has product type number 33 "X1" (hereinafter referred to as "product type X1," etc.), a production quantity 34 of "350 boards", a predicted production time 35 of "Tpa" (hereinafter referred to as "production time TPa," etc.), and a production deadline 37 of "12:00".

[0025] Furthermore, the production plan 20 includes a predicted changeover time 36, which is the time required for changeover operations such as replacing equipment resources in production equipment to change the type of mounted board produced on the component mounting line L. For example, the predicted changeover time 36 for changing the type of mounted board produced on the component mounting line L from type X1 to type X2 is "Tab" (hereinafter referred to as "changeover time Tab," etc.).

[0026] In Figure 2, the receiving unit 11 receives information (monitoring information) regarding errors that occur in the production equipment (printing device M2, printing inspection device M3, component mounting devices M4-M8, mounting inspection device M9) of the component mounting line L during the production of mounted boards, and stores it in the storage unit 19 as error information 21. The error information 21 includes errors detected and reported by production equipment such as the printing device M2 and component mounting devices M4-M8, as well as errors detected by production equipment (inspection equipment) such as the printing inspection device M3 and mounting inspection device M9 when inspecting the board (production product in progress).

[0027] When the receiving unit 11 receives error information 21, the option presentation unit 12 displays a response selection screen on the display unit 29 for users, such as operators or managers, to choose the next course of action. In other words, the option presentation unit 12 presents multiple options for identifying the fault location (equipment resource) of the production equipment based on the error information 21. The fault information creation unit 13 creates fault information 22 based on the option selected by the user from among the multiple options presented by the option presentation unit 12 and stores it in the storage unit 19. Alternatively, the fault information creation unit 13 may identify the fault location and create fault information 22 based on the error information 21 when the receiving unit 11 receives the error information 21, without relying on the selection result from the response selection screen described later.

[0028] Here, with reference to Figure 5, an example of the corresponding selection screen 40 displayed on the display unit 29 by the option presentation unit 12 will be described. The corresponding selection screen 40 displays an error information display field 41, a first corresponding selection field 42, a second corresponding selection field 43, a third corresponding selection field 44, a fourth corresponding selection field 45, a fifth corresponding selection field 46, a confirm button 47, and a cancel button 48. The error information display field 41 displays information identifying the production equipment and equipment resources where the error (or mistake) occurred, as well as the details of the error. The first to fifth corresponding selection fields 42 to 46 display the content of the options and include radio buttons for selecting an option.

[0029] When the OK button 47 is pressed while one of the radio buttons in the first to third correspondence selection fields 42 to 44 is selected, the fault information creation unit 13 creates fault information 22, and the production plan change unit 18 creates a revised production plan, which will be described later. For example, if the radio button in the third correspondence selection field 44 is selected, the fault information creation unit 13 creates fault information 22 that includes the fact that the fault location is "the tape feeder (F060) installed in the slot S6 of the front trolley of the component mounting device M5" and the error is "suction error".

[0030] In Figure 5, when the radio button in the fourth response selection field 45 is selected and the OK button 47 is pressed, the screen switches to a screen where the user can manually investigate the cause of the malfunction. When the radio button in the fifth response selection field 46 is selected and the OK button 47 is pressed, the screen switches to a screen where the component mounting line L produces mounted boards, and the production of mounted boards resumes. When the cancel button 48 is pressed, the operation on the response selection screen 40 is canceled.

[0031] In Figure 2, the equipment resource information 23 includes information identifying each equipment resource, its current location, and status, for each equipment resource used in the production equipment of component mounting line L and for each equipment resource stored in the preparation room PA. The predicted repair time information 24 includes the predicted average repair time for each type of equipment resource and type of failure. The standard changeover time information 25 includes the standard time for model changeover work to change the type of mounted board (type of product) produced in the production equipment, for each type of equipment resource and type of work. For example, in the case of a tape feeder, the standard changeover time information 25 includes the standard work time for tasks such as removing the tape feeder from component mounting equipment M4-M8, installing it, and replacing the carrier tape.

[0032] When creating a modified production plan (new production plan), the acquisition unit 14 acquires from the storage unit 19 the production plan 20, which includes the types of mounted boards (product types), production order, production delivery date 37, and correspondence list of production equipment and equipment resources used (equipment resource arrangement), as well as the standard changeover time included in the standard changeover time information 25, for creating a modified production plan (new production plan). The acquisition unit 14 also acquires failure information 22, which includes the failure location (equipment resource) of the production equipment producing the mounted boards based on the original production plan 20, which includes the production order of multiple types of mounted boards (products). The acquisition unit 14 also acquires the predicted repair time for the equipment resource at the failure location from the predicted repair time information 24.

[0033] In Figure 2, the similarity calculation unit 15 calculates the similarity between types of mounted boards based on the correspondence list (arrangement of equipment resources) of equipment resources for each type of mounted board (product number 33) obtained. Specifically, the similarity calculation unit 15 calculates the similarity between the equipment resources to be placed in the production equipment to produce the previous mounted board and the equipment resources to be placed in the production equipment to produce the next mounted board, based on the correspondence list of equipment resources. For example, the similarity calculation unit 15 calculates the ratio of the number of equipment resources that do not require replacement of equipment resources or carrier tapes during model changeover work to the total number of equipment resources to be placed in the production equipment. The calculated similarity is stored in the storage unit 19 as similarity information 26.

[0034] Here, we will explain an example of similarity information 26 with reference to Figure 4. Figure 4 shows the similarity 38 between five types of mounting boards (product types X1 to X5) included in the production plan 20 for one shift shown in Figure 3. For example, the similarity 38 between mounting boards of product type X2 and product type X3 is high at "88%". On the other hand, the similarity 38 between mounting boards of product type X2 and product type X5 is low at "45%".

[0035] In Figure 2, the model changeover time calculation unit 16 calculates the model changeover time required to produce the next mounted board from the previous mounted board, based on the standard changeover time included in the standard changeover time information 25 and the number of equipment resources and carrier tapes that need to be replaced during the model changeover operation. Here, the model changeover time is shorter when there are fewer equipment resources and carrier tapes to be replaced. That is, the higher the similarity 38 between the preceding and succeeding mounted boards, the fewer equipment resources and other items need to be replaced, and the shorter the model changeover time. The model changeover time may be calculated in advance when creating the production plan 20 and stored in the production plan 20 as the predicted changeover time 36.

[0036] The production sequence change unit 17 determines a new production sequence that allows for the production of mounted boards even while the faulty equipment resource is removed from the production equipment and repaired, based on the failure information 22, the equipment resource correspondence list (equipment resource placement), the model changeover time, the predicted repair time of the faulty equipment resource included in the predicted repair time information 24, and the production delivery date 37 included in the production plan 20. The production plan change unit 18 creates a new production plan based on the new production sequence determined by the production sequence change unit 17 and stores it in the storage unit 19 as the changed production plan 27.

[0037] Here, with reference to Figure 6, we will explain examples of the original production plan 20 and the revised production plan 27. Figure 6(a) shows the original production plan 20 shown in Figure 3, displayed in order of production time. That is, mounted circuit boards of product type X1 (lot A), product type X2 (lot B), product type X3 (lot C), product type X4 (lot D), and product type X5 (lot E) are produced in this order. The production order of product types X1 to X5 is optimized to have a high degree of similarity in the arrangement of equipment resources used for the production of preceding and succeeding product types, and to shorten the changeover time. Then, at a production time TPb1 elapsed since the start of production of mounted circuit board of product type X2, shown as "currently", the tape feeder (F060) installed in the slot S6 of the front trolley of component mounting machine M5 has failed, and production has been interrupted. Here, the remaining production time for mounted circuit board of product type X2 (the type of product being produced) is "TPb2" (TPb = TPb1 + TPb2).

[0038] Figure 6(b) shows the revised production plans (new production plans) for three different cases with predicted repair times TR1 to TR3, created by the production plan change unit 18. Here, the production of product types X2 and X3 requires the use of the equipment resource at the faulty location (tape feeder (F060)). In other words, production of product types X2 and X3 cannot start until the repair of the equipment resource at the faulty location (hereinafter referred to as "faulty resource") is completed. Also, the mounted boards of product types X4 and X5 are types of products that do not use the faulty resource.

[0039] In Case 1, the production order changing unit 17 does not consider the production delivery date 37, produces the mounting boards of product type X4 and product type X5 which do not use the failed resource until the repair of the failed resource is completed, produces the mounting boards of product type X2 and product type X3 which use the failed resource after the repair of the failed resource, and determines the production order such that the total model switching time is shortened. The model switching time calculation unit 16 calculates the model switching time in this production order.

[0040] In FIG. 6(b), specifically, the production order is determined such that product type X4 (66%), which has a higher similarity 38 to the initially suspended product type X2 than product type X5 (48%), is produced first, and then product type X5 is produced (see FIG. 4). This shortens the model switching times Tbd and Tde.

[0041] In Case 1, the repair of the failed resource is completed during the production of product type X5. That is, the predicted repair time TR1 is longer than the sum of the model switching time Tbd for switching from product type X2 to product type X4, the production time TPd of product type X4, and the model switching time Tde for switching from product type X4 to product type X5, and shorter than the sum of the model switching time Tbd, the production time TPd, the model switching time Tde, and the production time TPe of product type X5 (Tbd+TPd+Tde<TR1<Tbd+TPd+Tde+TPe). After product type X5, the production order is determined such that product type X2 (48%), which has a higher similarity 38 to product type X5 than product type X3 (40%), is produced, and then product type X3 is produced.

[0042] As described above, the production order changing unit 17 determines a new production order based on the predicted repair time TR1 so as to resume the remaining production of the type of product (the mounting board of product type X2) that was being produced before the failure after the completion of repair of the failed part (failed resource). In addition, based on the predicted repair time TR1, the production order changing unit 17 determines the new production order such that the type of product (the mounting board of product type X4) that can be completely produced before the completion of repair of the failed part is produced before the remaining production of the type of product (the mounting board of product type X2) that was being produced before the failure.

[0043] Furthermore, the production sequence change unit 17 determines a new production sequence based on the similarity 38 of the arrangement of equipment resources used to produce the previously produced type of product (mounted board of type X2) and other types of products (mounted boards of types X4 and X5). In addition, based on the failure information 22, the production sequence change unit 17 determines a new production sequence by changing the production sequence of at least the previously produced type of product (mounted board of type X2) and the remaining types of products (mounted boards of types X4 and X5) among the multiple types of products (mounted boards of types X2 to X5).

[0044] Furthermore, the production sequence change unit 17 determines a new production sequence such that the remaining production of the type of product being produced (mounted boards of type X2) follows the production of types of products that do not use the equipment resources (fault resources) at the faulty location (mounted boards of types X4 and X5). The production sequence change unit 17 also determines a new production sequence such that the total model changeover time (Tdb+Tde+Teb+Tbc) of the new production plan (changed production plan 27) is shorter than the sum of the model changeover times (Tbc+Tcd+Tde) of the original production plan 20 plus the predicted repair time TR1 (Tdb+Tde+Teb+Tbc <Tbc+Tcd+Tde+TR1)。

[0045] In Figure 6(b), Case 2 differs from Case 1 in that the production sequence change unit 17 determines a new production sequence based on the production deadline 37. In this example, the predicted repair time TR2 in Case 2 and the predicted repair time TR1 in Case 1 are the same. In Case 1, the production completion time for product X3 mounted boards exceeds the production deadline 37 (18:00). In Case 2, the production sequence change unit 17 determines the production sequence so that, once production of product X4 mounted boards is completed, it waits for the repair of the faulty resource to be completed before producing product X3 mounted boards, whose production deadline 37 is approaching. After that, the production sequence change unit 17 determines a new production sequence based on the similarity score 38.

[0046] In Case 2, the production completion time at which production of the mounting boards for all models X2 to X5 is completed is later than that in Case 1, but the changed production plan 27 is such that production is completed before the production delivery deadline 37 for all models X2 to X5. That is, in Case 2, there are no models that will suffer delivery delay. As described above, when there is no type of product that can complete production before the completion of repair of the faulty location, the production order changing unit 17 determines a new production order such that it waits for the repair of the faulty location and then produces the type of product (the mounting board of model X3) that uses the device resource at the faulty location (faulty resource).

[0047] In FIG. 6(b), Case 3 is a case where the predicted repair time TR3 is short, and repair of the faulty resource is completed while switching from model X2 to model X4 and producing the mounting board of model X4 (TR3 < Tbd + TPd). In this case, the production order changing unit 17 determines a new production order such that it waits for repair of the faulty resource and then resumes production of model X2. As described above, when there is no type of product that can complete production before the completion of repair of the faulty location (faulty resource) (before the predicted repair time TR3), the production order changing unit 17 determines a new production order such that it waits for the repair of the faulty location and then resumes the remaining production of the type of product (the mounting board of model X2) that was being produced.

[0048] Next, a production plan creation method for creating a production plan for production devices by the management computer 3 (production plan creation device) will be described along the flow of FIG. 7. When the component mounting line L (production line) is producing mounting boards (products) based on the production plan 20, if the receiving unit 11 receives error information 21 (Yes in ST1), the failure information creation unit 13 determines whether a failure has occurred in a device resource being used in the production device based on the error information 21 (ST2: failure determination step). If it is determined that a failure has occurred (Yes in ST2), the failure information creation unit 13 identifies the failure location (faulty resource) based on the error information 21 and creates failure information 22 (ST3: first failure information creation step). If it is determined that no failure has occurred (No in ST2), the process returns to the error information receiving step (ST1).

[0049] In Figure 7, when fault information 22 is created (ST3), a new production plan (modified production plan 27) is then created (ST4: modified production plan creation process). Next, the production plan modification unit 18 displays a modified production plan presentation screen (not shown) on the display unit 29, which allows the user to select whether or not to adopt the created modified production plan 27 (ST5: modified production plan presentation process). If the modified production plan 27 presented on the modified production plan presentation screen is adopted (Yes in ST6), the original production plan 20 is changed to the modified production plan 27 (ST7: modified production plan confirmation process), and production of the mounted boards continues based on the modified production plan 27. If the modified production plan 27 presented on the modified production plan presentation screen is rejected (Yes in ST6), the original production plan 20 remains unchanged and the production plan creation method flow ends.

[0050] Next, following the flow in Figure 8 and referring to Figure 6, we will explain in detail an example of the modified production plan creation process (ST4) (modified production plan creation method). First, the acquisition unit 14 acquires fault information 22, including the location of the fault (fault resource) of the production equipment (ST11: fault information acquisition process). Then, the acquisition unit 14 acquires the original production plan 20 for a predetermined period (for example, one shift), including the production delivery date 37 and the arrangement of equipment resources (correspondence list) (ST12: production plan acquisition process).

[0051] Next, the production order change unit 17 sorts the production order of the mounted boards of product types X3 to X5 (the remaining types of products), including the mounted board of product type X2 (the type of product that was being produced), based on the similarity 38 calculated by the similarity calculation unit 15 and the production deadlines 37 included in the production plan 20 (ST13: sorting step). Then, the production order is set based on the judgment conditions described later (ST14: production order setting step). The production order sorted in the sorting step (ST13) is set as the production order to be determined first. That is, product types X2 to X5 are sorted in order of proximity of production deadlines 37 and high similarity 38 between them.

[0052] In Figure 8, if the trials are completed for all production sequences (Yes in ST15), the production plan change unit 18 determines that it is not possible to create a modified production plan 27 that does not delay the production delivery date 37 (no solution) and terminates the creation of the modified production plan 27. Note that if it determines that it is not possible to create a modified production plan 27 that does not delay the production delivery date 37 (no solution) and terminates the creation of the modified production plan 27, a new production plan may be created based on a production sequence with a short delivery delay. If the pass / fail judgment (trial) of the set production sequence is not yet completed (No in ST15), the model changeover time calculation unit 16 calculates the model changeover time based on the equipment resource arrangement and standard changeover time information 25 (ST16: Model changeover time calculation process).

[0053] Next, the production sequence change unit 17 determines whether the total changeover time after the change is shorter than the total changeover time (Tbc + Tcd + Tde) of the original production plan 20 (ST17: first determination step). If the total changeover time after the change is shorter than the original total changeover time (Yes in ST17), the production sequence change unit 17 determines whether the predicted repair time is shorter than the changed production completion time (ST18: second determination step).

[0054] In Figure 8, if the predicted repair time is longer than the revised production completion time (No in ST18), the production sequence change unit 17 determines whether or not a delivery delay will occur (ST19: third determination step). If there is no delay in the production delivery date 37 (No in ST19), the new production plan creation step (ST25) is executed. That is, in the new production plan creation step (ST25), a new production plan (revised production plan 27) is created in which there is no delay in the production delivery date 37 for the production of all types X2 to X5 mounted boards.

[0055] Thus, even if a faulty resource is repaired in parallel with production, if the production completion time is shortened by changing the production sequence (Yes in ST17), production is completed before the repair of the faulty resource is completed (No in ST18), and there is no delivery delay (No in ST19), the production plan change unit 18 creates a modified production plan 27 based on the production sequence set by the production sequence change unit 17 (ST25). In other words, the production sequence change unit 17 determines the new production sequence such that the total model changeover time of the new production plan (modified production plan 27) is shorter than the total model changeover time of the original production plan 20.

[0056] In Figure 8, if the total changeover time after the change is longer than the total changeover time of the original production plan (No in ST17), the production sequence change unit 17 determines whether the difference between the total changeover time after the change and the total changeover time of the original production plan 20, i.e., whether the increase in changeover time is shorter than the predicted repair time (ST20: fourth determination step). If the increase in changeover time is shorter than the predicted repair time (Yes in ST20), the second determination step (ST18) is executed. If the increase in changeover time is longer than the predicted repair time (No in ST20), the production sequence change unit 17 swaps the second-highest (n=n+1) of the production sequence sorted in the sorting step (ST13) with the first-highest (m=1) (ST21), and executes the production sequence setting step (ST14).

[0057] If the increase in model changeover time due to a change in the production order exceeds the predicted repair time (No in ST20), it may be faster to stop production and perform repairs without changing the production order (for example, Case 3 in Figure 6). The fourth decision step (ST20) prevents such undesirable changes in the production order.

[0058] In Figure 8, if the predicted repair time is shorter than the revised production completion time (Yes in ST18), the production order change unit 17 swaps the top 1 (n=1) of the production order sorted in the sorting process (ST13) with the 2nd (m=m+1) (ST22), and then executes the production order setting process (ST14). If there is a delay in the production delivery date 37 (Yes in ST19), the production order change unit 17 swaps the top 2 (n=n+1) of the production order sorted in the sorting process (ST13) with the 1st (m=1) (ST23), and then executes the production order setting process (ST14).

[0059] Thus, steps (ST13) through (ST23) are production sequence change steps (ST24) in which the production sequence change unit 17, based on failure information 22, changes the production sequence of at least the type of product being produced (type X2 mounted board) and the remaining types of products (type X3 through X5 mounted boards) from among multiple types of products (type X2 through X5 mounted boards) to determine a new production sequence. Then, in the production plan change step (ST25), the production plan change unit 18 creates a new production plan (modified production plan 27) based on the new production sequence determined in the production sequence change step (ST24). This makes it possible to recreate the production plan so that production can continue even on a production line (component mounting line L) where production equipment or device resources have failed.

[0060] As another example of the modified production plan creation process (ST4) (modified production plan creation method), the production completion time may be calculated for all production sequences, and a new production plan (modified production plan 27) may be created (ST25) based on the production sequence that has no delays in the production delivery date 37 and has the earliest production completion time.

[0061] Next, following the flow in Figure 9, another embodiment of the production planning method, in which the management computer 3 (production planning device) creates a production plan for the production equipment, will be described. This other embodiment of the production planning method differs from the production planning method shown in Figure 7 in that the user selects a corresponding option based on error information 21. Below, the same steps as in the production planning method shown in Figure 7 are given the same numbers, and detailed explanations are omitted.

[0062] In Figure 9, when the receiving unit 11 receives error information 21 from the production equipment (Yes in ST1), the option presentation unit 12 displays a response selection screen 40 (Figure 5) on the display unit 29, which presents multiple options for identifying the fault location (faulty resource) based on the error information 21 (ST31: Option presentation process). When the creation of a modified production plan (first response selection field 42 to third response selection field 44) ​​is selected on the response selection screen 40 (Yes in ST32), the failure information creation unit 13 creates failure information 22 based on the option selected by the user from among the multiple options (ST33: Second failure information creation process).

[0063] Next, based on the fault information 22 created by the fault information creation unit 13, the modified production plan creation process (ST4) and the modified production plan confirmation process (ST7) are executed. If the creation of a modified production plan is not selected on the response selection screen 40 (No in ST32), the original production plan 20 is not modified and the flow of the other embodiment of the production plan creation method ends.

[0064] As described above, the management computer 3 of this embodiment is a production planning device that creates a production plan for a production device. This allows the production plan to be recreated so that production can continue even on a production line (component mounting line L) where production equipment has failed, based on an original production plan 20 which includes the production order of multiple types of products (mounted boards of product types X2 to X5). This includes an acquisition unit 14 which acquires failure information 22 including the location of a failure (failed resource) of a production device that is producing products based on an original production plan 20 which includes the production order of multiple types of products (mounted boards of product type X2 to X5). Based on the failure information 22, a production order change unit 17 which changes the production order of at least the type of product that was being produced (mounted boards of product type X2) and the remaining types of products (mounted boards of product types X3 to X5). [Industrial applicability]

[0065] The production plan creation apparatus and production plan creation method of the present invention have the effect of being able to recreate a production plan so that production can continue even on a production line where production equipment or equipment resources have failed, and are useful in the field of mounting components onto a substrate. [Explanation of Symbols]

[0066] 3. Management computer (production planning department) M2 Printing Equipment (Production Equipment) M3 Printing Inspection Machine (Production Equipment) M4-M8 Component Mounting Equipment (Production Equipment) M9 Assembly and Inspection Equipment (Production Equipment) Tab, Tbc, Tcd, Tde, Tbd, Teb, Tdc, Tcb, Tbe, Tbb Model switching time TR1~TR3 Estimated Repair Time

Claims

1. A production planning business device that creates a production plan for production equipment, An acquisition unit that acquires fault information, including the location of a malfunction in a production machine that is producing products based on an original production plan that includes the production sequence of multiple types of products, Based on the aforementioned failure information, a production sequence changing unit determines a new production sequence by changing the production order of at least the type of product that was being produced and the remaining types of products among the multiple types of products. The system includes a production plan modification unit that creates a new production plan based on the new production sequence, The aforementioned production sequence changing unit is Determine the new production sequence such that the remaining production of the previously produced type of product follows the production of the type of product that does not use the equipment resources of the faulty part. The aforementioned production plan change unit is A production planning device that creates a new production plan for producing products of a type that does not use the equipment resources at the faulty part of the production device until the equipment resources at the faulty part of the production device are repaired.

2. The acquisition unit is, A correspondence list is obtained showing the correspondence between the type of product and the equipment resources of the production apparatus used to produce the product. The aforementioned production sequence changing unit is A production plan creation apparatus according to claim 1, which determines the new production sequence based on the fault information and the corresponding list.

3. The acquisition unit is, Obtain the estimated repair time for the equipment resources at the aforementioned faulty location. The aforementioned production sequence changing unit is The production planning apparatus according to claim 1, which determines the new production sequence based on the predicted repair time, such that it produces products that do not use the equipment resources at the faulty location until the repair of the equipment resources at the faulty location is completed, and produces products that use the equipment resources at the faulty location after the repair of the equipment resources at the faulty location.

4. The aforementioned production sequence changing unit is The production planning apparatus according to claim 3, which determines the new production sequence based on the predicted repair time, so as to resume production of the remaining products of the type being produced after the repair of the faulty part is completed.

5. The aforementioned production sequence changing unit is The production planning apparatus according to claim 3, which determines the new production order based on the predicted repair time such that a type of product that can be produced before the repair of the faulty part is completed is produced before the remaining production of the type of product that was being produced.

6. The aforementioned production sequence changing unit is The production planning apparatus according to claim 5, which determines the new production sequence so as to wait for the repair of the faulty part and then resume production of the remaining products of the product that was being produced, if there are no products of a type that can be produced before the repair of the faulty part is completed.

7. The aforementioned production sequence changing unit is The production planning apparatus according to claim 5, which, if there are no products of a type that can be produced before the repair of the faulty part is completed, determines the new production sequence so as to wait for the repair of the faulty part and then produce products that use the equipment resources of the faulty part.

8. The acquisition unit is, Obtain the production delivery date for each type of the aforementioned multiple types of products. The aforementioned production sequence changing unit is A production plan creation device according to claim 1, which determines the new production sequence based on the aforementioned production delivery date.

9. The acquisition unit is, The arrangement of equipment resources used in the production of the aforementioned product is obtained, The aforementioned production sequence changing unit is The production planning apparatus according to claim 1, which determines the new production order based on the similarity of the arrangement of equipment resources used to produce the type of product that was being produced and several other types of products, so that the type of product that is relatively more similar to the type of product that was being produced is produced after the production of the type of product that was being produced is stopped, rather than the type of product that is relatively less similar to the type of product that was being produced.

10. The aforementioned production sequence changing unit is The production plan creation apparatus according to claim 1, which determines the new production sequence such that the total model changeover time of the new production plan is shorter than the total model changeover time of the original production plan.

11. The acquisition unit is, Obtain the estimated repair time for the equipment resources at the aforementioned faulty location. The aforementioned production sequence changing unit is The production plan creation device according to claim 1, which determines the new production sequence such that the total model changeover time of the new production plan is shorter than the time obtained by adding the predicted repair time to the model changeover time of the original production plan.

12. A receiving unit that receives error information from the production apparatus, The system further comprises a fault information creation unit that identifies the fault location based on the error information and creates the fault information, The acquisition unit is, The production plan creation apparatus according to claim 1, which acquires the failure information created by the failure information creation unit.

13. A receiving unit that receives error information from the production apparatus, A choice presentation unit that presents multiple options for identifying the fault location based on the error information, The system further comprises a fault information creation unit that creates fault information based on the option selected by the user from among the aforementioned multiple options, The acquisition unit is, The production plan creation apparatus according to claim 1, which acquires the failure information created by the failure information creation unit.

14. A production planning business method for creating a production plan for production equipment, An acquisition process to acquire fault information, including the location of a malfunction in a production machine that is producing products based on an original production plan that includes the production sequence of multiple types of products, Based on the aforementioned failure information, a production sequence change step is performed to determine a new production sequence by changing the production sequence of at least the type of product that was being produced and the remaining types of products among the multiple types of products. The process includes a production plan change step of creating a new production plan based on the new production sequence, The aforementioned production sequence change process is: Determine the new production sequence such that the remaining production of the previously produced type of product follows the production of the type of product that does not use the equipment resources of the faulty part. The aforementioned production plan change process is: A production plan creation method, which involves creating a new production plan in which the production apparatus produces a type of product that does not use the equipment resources at the faulty part until the equipment resources at the faulty part are repaired.

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