Production management method and production management system

Abstract

In a system comprising: a production line provided on a production floor; a plurality of cameras installed on the production floor or the production line and connected to a network; and a terminal connected to the network, this production management method includes selecting from the terminal an object camera to be used among the plurality of cameras, displaying an image captured by the object camera on a display unit of the terminal, and confirming the state of the production line or the state of a worker working on the production line from the image displayed on the display unit.

Description

Production management method and production management system

[0001] This specification discloses a production management method and a production management system.

[0002] Conventionally, a work management system has been proposed that, when an error occurs in equipment installed on a production floor, selects a target worker from among multiple workers based on error information, outputs instruction information indicating that the target worker should perform confirmation work to confirm the accuracy of the work, acquires video data of the target worker performing the work from a camera installed on the production floor, analyzes the acquired video data to calculate the accuracy of the confirmation work, and outputs guidance information (information for conducting education and training or on-the-job training) corresponding to the calculated accuracy (see, for example, Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2022-124655

[0004] However, although Patent Document 1 describes calculating the accuracy of workers' confirmation work from video data captured by cameras on the production floor, there is still room for improvement, as production line managers and others want to be able to easily grasp the status of the production line and the status of the workers working on the production line.

[0005] The main purpose of the present disclosure is to enable a production line manager or the like to more easily grasp the status of a production line and the status of workers working on the production line without having to go to the site.

[0006] The present disclosure has adopted the following means to achieve the above-mentioned main object.

[0007] The production management method disclosed herein is a production management method for managing production in a system comprising a production line set up on a production floor, a plurality of cameras installed on the production floor or the production line and connected to a network, and a terminal connected to the network, and comprises the steps of: selecting a camera to be used from the plurality of cameras on the terminal; displaying an image captured by the target camera on a display unit of the terminal; and checking the status of the production line or the status of workers working on the production line from the image displayed on the display unit.

[0008] In the production management method disclosed herein, a production line manager or the like can select a target camera from multiple cameras installed on the production floor or production line and view the image displayed on the display unit of a terminal, thereby more easily understanding the status of the production line and the status of the workers working on the production line without having to go to the site.

[0009] The production management system disclosed herein is a production management system that manages a production line set up on a production floor, and includes: a plurality of cameras that are installed on the production floor or on the production line and connected to a network; and a terminal connected to the network, the terminal having a display unit and a control unit that accepts selection of a target camera from among the plurality of cameras and displays an image captured by the target camera on the display unit when the startup waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when an abnormality occurs in any of the devices on the production line.

[0010] In the production management system disclosed herein, when the startup wait time of a device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when an abnormality occurs in any of the devices on the production line, the system accepts the selection of a target camera from among multiple cameras installed on the production floor or production line, and displays an image captured by the target camera on the display unit of a terminal. The production line manager or the like can view the image displayed on the display unit of the terminal at the appropriate time, allowing them to more appropriately understand the status of the production line and the status of the workers working on the production line without having to go to the site.

[0011] FIG. 1 is a schematic diagram of a production line and a production management system. FIG. 2 is a flowchart showing an example of production management processing. FIG. 3 is an explanatory diagram showing an example of the operation of the production management system when a startup wait occurs in a device on the line (U1). FIG. 4 is an explanatory diagram showing an example of the operation of the production management system when a line stop occurs (U2). FIG. 5 is an explanatory diagram showing an example of the confirmation procedure by a line manager when checking the status of the production line or workers working on the production line (U3). FIG. 6 is an explanatory diagram showing an example of the operation of the production management system when an abnormality occurs in a device on the line (U11). FIG. 7 is an explanatory diagram showing an example of the confirmation procedure by a worker or line manager when checking the status of the equipment and boards on the line (U12).

[0012] Next, embodiments of the present disclosure will be described with reference to the drawings.

[0013] 1 is a schematic diagram of a production line 1 and a production management system 10. The production line 1 is a line that produces boards on which electronic components (components) are mounted, and includes a printing device 2, a print inspection device, a storage device 3, multiple component mounting devices 4, a mounting inspection device (not shown), a reflow device 5, a reflow inspection device (not shown), a loader 6, and a line management device 7 that manages the entire production line 1. On the production line 1, the printing device 2, the print inspection device, the storage device 3, multiple component mounting devices 4, the mounting inspection device, the reflow device 5, and the reflow inspection device are arranged in a line in this order along the transport direction of the board S.

[0014] The printing device 2 prints solder onto the wiring pattern of the substrate S. The printing device 2 includes a substrate transport device that transports the substrate S, a substrate support device that supports the substrate S so that the printed surface of the substrate S contacts the underside of the screen mask, a print head including a squeegee, a head moving device that moves the print head, a solder replenishing device that replenishing solder onto the screen mask, and a print control device that controls the entire printing device 2. The print inspection device inspects the condition of the solder printed on the substrate S by the printing device 2.

[0015] Storage device 3 stores feeders that are scheduled to be used by component mounting devices 4, and stores used feeders that have been used by component mounting devices 4. Loader 6 loads feeders that are scheduled to be used into component mounting devices 4 and collects used feeders from component mounting devices 4. Loader 6 includes a loader main body including a storage section that stores feeders, a feeder transfer device that transfers feeders between the storage section and storage device 3 or component mounting devices 4, a loader transfer device that moves the loader main body along production line 1 between storage device 3 and each component mounting device 4, and a loader control device that controls the entire loader 6.

[0016] The component mounting device 4 picks up components supplied from the feeders and mounts them at mounting positions on the board S, and includes a feeder table on which multiple feeders are attached, a board transport device that transports the board S, a board support device that supports the board S, a mounting head that holds one or more suction nozzles so that they can be raised and lowered, a head moving device that moves the mounting head horizontally (X and Y directions), a mark camera, a parts camera for checking the suction state of the components picked up by the suction nozzles, a nozzle station that accommodates replacement suction nozzles, and a mounting control device that controls the entire component mounting device 4. The mounting inspection device inspects the mounting state of the components mounted on the board S by the component mounting device 4.

[0017] The reflow device 5 heats the board S to melt and solidify the solder on the board S, and electrically connects the components mounted on the board S to the wiring pattern of the board S. The reflow inspection device inspects the condition of the components on the board S that have been subjected to the reflow process.

[0018] The line management device 7 is a computer including a CPU, ROM, RAM, and storage device. The storage device stores a production schedule and production information related to the production of boards S. The production schedule includes the number of boards S to be produced for each type of board S when multiple types of boards S are produced, the production start time, and other information. The production information includes component information related to the components to be mounted by each of the multiple component mounting devices 4, nozzle information related to the suction nozzles used to pick up the components, the mounting sequence of each component, and the target mounting position. The line management device 7 is connected to the printing device 2, the print inspection device, the storage device 3, the multiple component mounting devices 4, the mounting inspection device, the reflow device 5, and the reflow inspection device via wired or wireless connections, and transmits various command signals to each device and receives status information from each device (e.g., information indicating the operating status, such as in production, stopped, or if an error has occurred).

[0019] The production management system 10 is primarily used to check the status of the production line 1 and the status of the worker M working on the production line 1, and comprises a production management device 11 that controls the entire production management system 10, multiple floor cameras 21, and multiple equipment cameras 22. The production management device 11 is a computer that includes a CPU 11a, a ROM 11b, a RAM 11c, and a storage unit 11d such as an HDD or SSD, and is also connected to input devices 12 such as a keyboard and a mouse, and a display 13.

[0020] The floor cameras 21 are installed on the ceiling or walls of the production floor F (production line 1) so as to capture images of the production floor F (production line 1) from a position that overlooks the entire production floor. The device cameras 22 capture images of the interior of each device (e.g., the printing device 2 or the component mounting device 4) on the production line 1. In this embodiment, multiple device cameras 22 are installed for each device so as to capture images of the interior of the device from different positions. In this embodiment, each floor camera 21 and each device camera 22 includes a pan adjustment mechanism that rotates the camera body horizontally, a pan adjustment motor, a tilt adjustment mechanism that rotates the camera body vertically, a tilt adjustment motor, a focus adjustment mechanism that adjusts the focus, and a focus adjustment motor. Each floor camera 21 and each device camera 22 can adjust the imaging angle (pan angle or tilt angle) of the camera body or the focus by driving the pan adjustment motor, tilt adjustment motor, or focus adjustment motor via remote control from an external device (e.g., the production management device 11 or a mobile terminal carried by the worker M) via the network 14.

[0021] Next, a description will be given of the operation of the production management system 10. Fig. 2 is a flowchart showing an example of production management processing executed by the CPU 11a of the production management device 11.

[0022] In the production management process, the CPU 11a of the production management device 11 first acquires the status (status information) of each device on the production line 1 from the line management device 7 (S100). Next, the CPU 11a determines whether any of the devices on the production line 1 is in a startup standby state based on the acquired status information (S102). Here, the startup standby state refers to a state in which production preparation (setup change) is completed, the production start time arrives, and the device is waiting for the operator M to press the startup button. If the CPU 11a determines that any of the devices is in a startup standby state, it determines whether the startup standby time exceeds a threshold (S104). If the production management device 11 determines that the startup standby time exceeds the threshold, it proceeds to S114.

[0023] On the other hand, if the CPU 11a determines in S102 that none of the devices are in a startup waiting state or if it determines in S104 that the startup waiting time has not exceeded the threshold, it determines whether the production line 1 is in a line stopped state (S106). If the CPU 11a determines that the line is in a line stopped state, it determines whether the line stopped time has exceeded the threshold (S108). If the CPU 11a determines that the line stopped time has exceeded the threshold, it proceeds to S114.

[0024] On the other hand, if the CPU 11a determines in S106 that the production line 1 is not stopped or determines in S108 that the stop time has not exceeded the threshold, it determines whether an error has occurred in any of the devices on the production line 1 and an abnormal device state has occurred (S110). If the CPU 11a determines that the device is not in an abnormal device state, it ends this process.

[0025] When the CPU 11a determines in S102 or S104 that any device on the production line 1 is in a startup waiting state and the startup waiting time exceeds a threshold, when the CPU 11a determines in S106 or S108 that the production line 1 is stopped and the stop time exceeds a threshold, or when the CPU 11a determines that any device is in an abnormal state in S110, the CPU 11a notifies the line manager or the worker M of the status of the device and a countermeasure for the status (S112). The notification to the line manager is performed by displaying the status on the display 13 of the production management device 11. The notification to the worker M is performed by transmitting the status of the device to a mobile terminal carried by the worker M and displaying it on the display of the mobile terminal. For example, when any device on the production line 1 is in a startup waiting state, as shown in FIG. 3, when the startup waiting time exceeds a threshold, the CPU 11a notifies the worker M of the startup waiting state, the identification information for the device, and the message that a startup button should be pressed. The worker M can then go to the device and press the startup button. Furthermore, for example, when production line 1 is in a stopped state, as shown in FIG. 4, a message indicating that a stopped state has occurred is sent to worker M or the line manager when the line stop time (waiting time for the previous process) exceeds a threshold, thereby encouraging worker M or the line manager to take action regarding the stopped state of production line 1.

[0026] Next, the CPU 11a displays the video from the floor camera 21 and thumbnail images of each device camera 22 on the display 13 (S114). The CPU 11a then accepts the selection of a device camera 22 (target camera) to be used to check the internal state of a device among the devices on the production line 1 (S116). The target camera is selected, for example, by a line manager operating the input device 12 to select an image of which the user wishes to view details from the thumbnail images of each device camera 22 displayed on the display 13. Once the target camera is selected, the CPU 11a accepts the operation of the input device 12 to remotely adjust the angle of the target camera (S118) and also accepts the operation of the input device 12 to remotely adjust the focus of the target camera (S120). The CPU 11a then displays the video from the target camera on the display 13 (S122) and terminates this process. The CPU 11a may also store (record) the video from the target camera in the memory unit 11d.

[0027] For example, if production line 1 stops, the line manager who receives the notification of the line stoppage checks the notification message, as shown in FIG. 5 , and then checks the status of production line 1 and the status of worker M working on production line 1 from the video footage from floor camera 21. Next, to investigate the cause of the line stoppage, the line manager selects a device camera 22 (target camera) to use from among the multiple device cameras 22, adjusts the angle and focus of the target camera, and then checks the status of the corresponding device from the video footage from the target camera displayed on display 13. This allows the line manager to determine an appropriate countermeasure tailored to the device status and instruct worker M. For example, if a component suction abnormality occurs in a device and the video footage from device camera 22 of the corresponding device shows that a component has fallen onto a circuit board, the line manager can instruct worker M to remove the component that has fallen onto the circuit board.

[0028] The floor camera 21 and the equipment camera 22 may be remotely controlled and the images viewed by the worker M may be viewed using a mobile device carried by the worker M. For example, if an abnormality occurs in any of the equipment on the production line 1, the worker M may receive a notification of the abnormal equipment status as shown in FIG. 6 and understand the details of the abnormality and the countermeasures for the equipment by checking the notification message. Then, as shown in FIG. 7, in cases where the worker M is unable to determine whether to implement the countermeasures for the equipment abnormality or where multiple component suction abnormalities have occurred and components may have fallen onto the board S, the worker M may check the status of the production line 1 from the images captured by the floor camera 21, select the equipment camera 22 to be used (target camera) from the multiple equipment cameras 22, adjust the angle and focus of the target camera, and then view the interior of the equipment using the target camera's image. If there is no abnormality in the equipment, the worker M can cancel the abnormal equipment status and resume production, and remove any components that have fallen onto the board S.

[0029] Here, the correspondence between the main elements of the embodiment and the main elements of the present disclosure described in the claims will be explained. That is, the production line 1 of the present embodiment is an example of a production line of the present disclosure, the floor camera 21 and the equipment camera 22 are examples of cameras, the production management device 11 and the mobile terminal are examples of terminals, and the display 13 is an example of a display unit. Also, the floor camera 21 is an example of a first camera, and the equipment camera 22 is an example of a second camera.

[0030] It goes without saying that the present disclosure is not limited to the above-described embodiments, and can be embodied in various forms as long as they fall within the technical scope of the present disclosure.

[0031] For example, in the above-described embodiment, the production management system 10 is provided with multiple floor cameras 21, but it may be provided with only one floor camera 21. Also, the production management system 10 is provided with multiple equipment cameras 22 for each device on the production line 1, but it may be provided with one equipment camera 22 for each device.

[0032] In the above-described embodiment, the production management system 10 is provided with a plurality of floor cameras 21 and a plurality of equipment cameras 22, but one of the floor cameras 21 and the equipment cameras 22 may be omitted.

[0033] In the above-described embodiment, the floor camera 21 and the device camera 22 are configured so that their angles and focuses can be adjusted by remote control from the production management device 11 or a mobile terminal, but the focus may be adjusted automatically after the angle is adjusted by remote control. Also, the angle adjustment may be manually performed in advance by the worker M or the like.

[0034] In the production management method disclosed hereinabove, a production line manager or the like can select a target camera from multiple cameras installed on the production floor or production line and view the image displayed on the display unit of a terminal, thereby more easily grasping the status of the production line and the status of the workers working on the production line without having to go to the site.

[0035] In the production management method of the present disclosure, the target camera may be adjusted, including by adjusting the angle or focus, by remote control from the terminal, and the image captured by the target camera may be displayed on the display unit of the terminal. In this way, the target camera can clearly display images of necessary locations, allowing the line manager or the like to more accurately grasp the state of the production line and the state of the workers working on the production line.

[0036] In addition, in the production management method disclosed herein, the multiple cameras may include a first camera that captures images of the entire production line and multiple second cameras that capture images of the inside of each device on the production line, and the images captured by the first camera may be displayed on the display unit, and a target second camera to be used from the multiple second cameras may be selected from the terminal, and the images captured by the target second camera may be displayed on the display unit of the terminal. In this way, by sequentially switching between images from the first camera and the second camera, the status of the production line and the status of workers working on the production line can be efficiently confirmed.

[0037] Furthermore, in the production management method of the present disclosure, when the startup waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when an abnormality occurs in any of the devices on the production line, the terminal may be notified of this fact. In this way, a line manager or the like can check the status of the production line by viewing the camera images at an appropriate time.

[0038] Furthermore, the present disclosure can be implemented in the form of a production management system instead of a production management method. In the production management system of the present disclosure, when the startup wait time of a device on the production line exceeds a threshold, when the production line downtime exceeds a threshold, or when an abnormality occurs in any of the devices on the production line, the system accepts the selection of a target camera from among multiple cameras installed on the production floor or production line, and displays an image captured by the target camera on a terminal display. A production line manager or the like can view the image displayed on the terminal display at the appropriate time, allowing them to more appropriately understand the status of the production line and the status of workers working on the production line without having to go to the site.

[0039] This specification also discloses the technical idea of ​​changing "the production management method according to claim 1 or 2" in claim 4 of the original application to "the production management method according to any one of claims 1 to 3."

[0040] The present disclosure can be used in the manufacturing industry for production lines and production control systems.

[0041] 1 Production line, 2 Printing device, 3 Storage device, 4 Component mounting device, 5 Reflow device, 6 Loader, 7 Line management device, 10 Production management system, 11 Production management device, 11a CPU, 11b ROM, 11c RAM, 11d Storage unit, 12 Input device, 13 Display, 14 Network, 21 Floor camera, 22 Equipment camera, F Production floor, M Worker, S Board.

Claims

1. A production management method for managing production in a system comprising a production line installed on a production floor, a plurality of cameras installed on the production floor or on the production line and connected to a network, and a terminal connected to the network, comprising the steps of: selecting a camera to be used from the plurality of cameras from the terminal; displaying an image captured by the target camera on a display unit of the terminal; and confirming the state of the production line or the state of a worker working on the production line from the image displayed on the display unit.

2. A production management method as claimed in claim 1, comprising the steps of: adjusting the camera of the target, including adjusting the angle or focus, by remote control from the terminal; and displaying an image captured by the camera of the target on a display unit of the terminal.

3. A production management method as claimed in claim 1 or 2, wherein the plurality of cameras comprises a first camera which images the entire production line and a plurality of second cameras which each image the inside of each device on the production line, the image captured by the first camera is displayed on the display unit, a target second camera to be used from among the plurality of second cameras is selected from the terminal, and the image captured by the target second camera is displayed on the display unit of the terminal.

4. A production management method as claimed in claim 1 or 2, wherein when the startup waiting time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when an abnormality occurs in any of the devices on the production line, a notification to that effect is sent to the terminal.

5. A production management system that manages a production line installed on a production floor, comprising: a plurality of cameras installed on the production floor or on the production line and connected to a network; and a terminal connected to the network, the terminal having a display unit and a control unit that accepts selection of a target camera from among the plurality of cameras and displays an image captured by the target camera on the display unit when the startup wait time of each device on the production line exceeds a threshold, when the stop time of the production line exceeds a threshold, or when an abnormality occurs in any of the devices on the production line.