Production assistance device and production assistance method

Abstract

This production assistance device includes: a process design unit that executes a process design process of allocating the type and quantity of components to be mounted in a mounting process by a plurality of component mounting machines to the plurality of component mounting machines; and a method setting unit that executes a method setting process of setting a replenishment method for each of the components allocated to the plurality of component mounting machines on the basis of method information indicating the replenishment method applicable to each type of the components supplied to the component mounting machines during production of a product baseboard.

Description

Production support device and production support method

[0001] The present invention relates to a production support device and a production support method.

[0002] The production support device and production support method support the production of product boards by component placement machines. Patent Document 1 discloses a configuration for allocating component types and quantities to a production line in which multiple component placement machines are arranged side by side so that each cycle time is equal. Patent Document 1 also describes arranging multiple feeders that are equipped on the component placement machines to supply components, thereby improving production efficiency.

[0003] International Publication No. 2020 / 157845

[0004] To continue producing product boards, it is necessary to replenish consumed parts. Various methods for replenishment of parts are available, each with its own advantages and disadvantages. Furthermore, the applicability of a replenishment method varies depending on the type of feeder and the type of parts. Therefore, even if a cycle time equalization process is performed before production, depending on the set part replenishment method, the cycle time may be longer than planned, and the expected production efficiency may not be maintained.

[0005] An object of the present specification is to provide a production support device and a production support method that can maintain the production efficiency of a production line.

[0006] This specification discloses a production support device that is applied to a production line in which a plurality of component mounting machines arranged in a line in the transport direction of a board perform a mounting process to mount components on the board to produce product boards, and that includes: a process design unit that performs a process design process to allocate the types and quantities of components to be mounted in the mounting process by the plurality of component mounting machines to the plurality of component mounting machines; and a method setting unit that performs a method setting process to set the supply method for each of the components allocated to the plurality of component mounting machines based on method information that indicates the supply method applicable for each type of component to be supplied to the component mounting machines during the production of the product boards.

[0007] This specification discloses a production support method that is applied to a production line in which a plurality of component mounting machines arranged in a line in the transport direction of a board perform a mounting process to mount components on the board to produce product boards, and that includes a process design step of executing a process design process to allocate the types and quantities of components to be mounted in the mounting process by the plurality of component mounting machines to the plurality of component mounting machines, and a method setting step of executing a method setting process to set the supply method for each of the components allocated to the plurality of component mounting machines based on method information indicating the supply method applicable to each type of component to be supplied to the component mounting machines during the production of the product boards.

[0008] This specification also discloses the technical idea of ​​changing "the production support device according to claim 3 or 4" in claim 6 originally filed to "the production support device according to any one of claims 3-5," and the technical idea of ​​changing "the production support device according to claim 3 or 4" in claim 7 originally filed to "the production support device according to any one of claims 3-6." This specification also discloses the technical idea of ​​changing "the production support device according to any one of claims 2-4" in claim 8 originally filed to "the production support device according to any one of claims 2-7," and the technical idea of ​​changing "the production support device according to any one of claims 2-4" in claim 10 originally filed to "the production support device according to any one of claims 2-9."

[0009] With this configuration, a supply method is appropriately set for components allocated to multiple component placement machines that make up the production line, which helps ensure that production on the production line is carried out within the scheduled cycle time, thereby maintaining the expected production efficiency.

[0010] FIG. 1 is a schematic diagram showing a production system to which a production support device is applied. FIG. 2 is a top view schematically showing a component mounting machine. FIG. 3 is a schematic diagram showing the appearance of a feeder and a reel as viewed from the side. FIG. 4 is a schematic diagram showing a state in which a replenishment carrier tape is set in an auto-loading feeder. FIG. 5 is a plan view showing a state in which a replenishment carrier tape has been spliced ​​to a carrier tape in use. FIG. 6 is a diagram showing various data in a functional block diagram of a production system including a production support device. FIG. 7 is a diagram showing an example of the results of process design. FIG. 8 is a graph showing the relationship between each placement process and cycle time in the results of process design. FIG. 9 is a flowchart showing production support processing.

[0011] 1. Overview of the Production Support Device and Production Support Method The production support device 60 and production support method support the production of product boards by the component placement machines 10. The production support device 60 supports production by optimizing the placement processes executed by each of the multiple component placement machines 10 that make up the production line Ln. Optimizing the placement processes includes shortening the cycle time, which is the time required for the placement process, improving the uniformity of the cycle time, and improving the continuity of production. For example, the production support device 60 performs processing to rearrange the placement order of components or the supply positions of components to shorten the component movement path.

[0012] The component mounting machine 10 described above performs a mounting process for mounting components on a board as a predetermined substrate-related operation. As shown in FIG. 1 , the production line Ln is configured by arranging a plurality of substrate-related operation machines in a line in the board transport direction. Each of the plurality of substrate-related operation machines is communicably connected to a line management device 55 and a host computer 51, which control the production line Ln as a whole. The line management device 55 manages the production line Ln in which the line management device 55 is installed. The production line Ln includes a plurality of substrate-related operation machines, such as solder printing machines, a plurality of component mounting machines 10, a reflow furnace, and an inspection machine.

[0013] In this embodiment, the production system Sy for board products may be configured with a plurality of production lines Ln (Ln1, Ln2, ...). Note that the configuration of each of the plurality of production lines Ln may be appropriately added to or modified depending on, for example, the type of board product to be produced. Specifically, the plurality of production lines Ln may be appropriately equipped with substrate-related operation machines such as a buffer device that temporarily holds the transported boards, a substrate supply device, a substrate inverting device, various inspection devices, a shield mounting device, an adhesive application device, and an ultraviolet irradiation device.

[0014] The host computer 51 includes a storage device 52, as shown in FIG. 6. The storage device 52 stores a production plan M1, product information M2, inventory information M3, and method information M4. As shown in FIG. 7, the production plan M1 indicates the types of board products to be produced (product types: U1, U2, U3, ...), the planned production quantities (T1, T2, T3, ...), and the production sequence thereof. The product information M2 indicates the types of components (Pa, Pb, Pc, ...) required for each type of board product (U1, U2, U3, ...). The product information M2 indicates the number of components consumed for each type of component when producing one board product of a predetermined type.

[0015] The inventory information M3 indicates the number of parts in stock for each part type and identification code (reel ID). For example, if the carrier tape 41 for the same part type is wound on different reels 40, the same part type is managed with different identification information (reel IDs) assigned, as shown in the inventory information M3. The inventory information M3 also includes the size of the reel 40 on which the carrier tape 41 is wound. For new parts, the reel size (Rz9, Rz11, ...) correlates with the remaining quantity (nTa1, nTa2, ...).

[0016] The inventory information M3 also includes the current location. The location of a component may include, for example, a specific storage warehouse 56 (W01), a production line (Ln1, Ln2), a component transport vehicle, or a setup area. The storage warehouse 56 stores feeders 122 loaded with reels 40 or carrier tapes 41. The inventory information M3 is updated based on inventory information for the storage warehouse 56, consumption information for the component mounting machine 10, and the like. Details of the method information M4 will be described later.

[0017] 2. Configuration of the component mounting machine 10 2-1. Board transport device 11 As shown in Fig. 2, the component mounting machine 10 includes a board transport device 11. The board transport device 11 sequentially transports the boards 91 in a transport direction and positions the boards 91 at predetermined positions within the machine.

[0018] 2-2. Component Supply Device 12 The component mounting machine 10 is equipped with a component supply device 12. The component supply device 12 supplies components to be mounted on the board 91. The component supply device 12 has feeders 122 set in multiple slots 121. The feeders 122 may be tape feeders, stick feeders, bulk feeders, or the like. The tape feeder feeds and moves the carrier tape 41 (see FIGS. 3 to 5) to supply components so that they can be picked up. The component supply device 12 is equipped with a reel holder 123 that holds the reel 41 around which the carrier tape 41 is wound. The reel holder 123 may be attached to a pallet having slots 121 formed therein, or may be attached to the feeder 122 as shown in FIG.

[0019] 2-3. Component Transfer Device 13 The component mounting machine 10 is equipped with a component transfer device 13. The component transfer device 13 transfers components supplied by the component supply device 12 to predetermined mounting positions on the board 91. The component transfer device 13 is equipped with a head drive device 131, a movable table 132, a mounting head 133, and a suction nozzle 134. The head drive device 131 moves the movable table 132 in horizontal directions (X and Y directions) using a linear motion mechanism. The mounting head 133 is detachably fixed to the movable table 132 by a clamp member (not shown) and is provided so as to be movable horizontally within the machine.

[0020] The mounting head 133 supports a plurality of suction nozzles 134 that are rotatable and movable up and down. The suction nozzles 134 are holding members that can pick up and hold components supplied by the feeder 122. The suction nozzles 134 use supplied negative pressure air to pick up the components supplied by the feeder 122. A chuck or the like that grips and holds components can be used as the holding member attached to the mounting head 133.

[0021] In this embodiment, the mounting head 133 includes eight holders (not shown) arranged at equal intervals on a ring centered on an R axis extending in the vertical direction. A suction nozzle 134 used for the mounting process is attached to each of the eight holders. The eight suction nozzles 134 are rotatable about the R axis and also about a Q axis passing through the center of each nozzle and extending in the vertical direction.

[0022] 2-4. Component camera 14, board camera 15 The component mounting machine 10 is equipped with a component camera 14 and a board camera 15. The component camera 14 and the board camera 15 are digital imaging devices having imaging elements such as CMOS. The component camera 14 and the board camera 15 capture images based on control signals and send image data acquired by the images. The component camera 14 is configured to be able to capture images of the components held by the suction nozzle 134 from below. The board camera 15 is mounted on a moving stage 132 so as to be movable horizontally integrally with the mounting head 133. The board camera 15 is configured to be able to capture images of the board 91 from above.

[0023] Furthermore, in addition to capturing an image of the surface of the circuit board 91, the circuit board camera 15 can also capture an image of various devices within the movable range of the movable table 132. For example, the circuit board camera 15 can capture an image of the supply area where the feeder 122 supplies components, as well as identification codes and reference marks provided on the feeder 122 and various components, within the field of view of the camera. In this way, the circuit board camera 15 can be used to capture images of different devices in order to obtain image data to be used for various image processing.

[0024] 2-5. Control Device 16 The component mounting machine 10 is equipped with a control device 16. The control device 16 is mainly composed of a CPU, various memories, and a control circuit. The control device 16 acquires and stores various data, such as a control program used to control the mounting process and component data, from the host computer 51 or the line management device 55. The control program indicates the mounting position, mounting angle, and component type of components to be mounted on the board 91 in the mounting process in the planned mounting order. The component data indicates shape data for each type of component, the maximum allowable movement speed (acceleration), and the pickup position (for example, the position at which the component comes into contact with the suction nozzle 134).

[0025] The mounting process includes a process of repeating a PP cycle (pick-and-place cycle), which includes a pickup cycle and a mounting cycle, multiple times. The "pick-up cycle" refers to a process of repeating a pickup operation, in which the suction nozzle 134 picks up components supplied by the component supply device 12, multiple times.

[0026] The above-mentioned "mounting cycle" refers to the process of sequentially mounting picked components onto the board 91, and more specifically, to the process of repeating a mounting operation multiple times to mount components at a predetermined mounting position on the board 91 at a predetermined mounting angle. In this way, the control program may have a preset execution order for a PP cycle, which is made up of multiple picking and mounting operations grouped together, taking into consideration the number of suction nozzles 134 supported by the mounting head 133 (eight in this embodiment), the movement distance of the mounting head 133, etc.

[0027] The control device 16 executes a process for recognizing the holding state of the components held by each of the multiple holding members (suction nozzles 134). Specifically, the control device 16 processes image data acquired by image capture by the component camera 14, and recognizes the position and angle of each component relative to the reference position of the mounting head 133. Note that in addition to the component camera 14, the control device 16 may also process image data acquired by, for example, a head camera unit integrally provided on the mounting head 133 capturing an image of the component from the side, below, or above.

[0028] In the mounting process, the control device 16 controls the mounting operation by the mounting head 133 so that the component is mounted on the board 91 in a predetermined orientation. At this time, the control device 16 controls the mounting operation based on the recognized holding state of the component. In other words, the control device 16 corrects the position of the mounting head 133 and the angle of the suction nozzle 134 about the Q axis so as to correct any positional and angular deviations of the component held by the suction nozzle 134 relative to the Q axis (the axis of rotation of the suction nozzle 134). As a result, the component held by the suction nozzle 134 is mounted at a predetermined mounting position and angle instructed by the control program.

[0029] 3. Carrier Tape 41, Feeder 122 The feeder 122 includes a normal tape feeder 20 shown in FIG. 3 and an autoloading feeder 30 shown in FIG. 4. Here, as shown in FIG. 5, the carrier tape 41 accommodates one component 92 in each of a plurality of cavities 421 formed at regular intervals in the base tape 42. The openings of the plurality of cavities 421 are closed by cover tape 43 to prevent the components 92 from falling out. The base tape 42 is formed with feed holes 422 that engage with the sprocket teeth of the feeder 122 or the tape transport device of the splicing device 57.

[0030] As shown in Figure 3, carrier tape 41 is inserted into tape feeder 20 from the rear side (left side in Figure 3) of feeder body 21, and a sprocket of tape transport device 22 provided below the tape transport path is driven. This rotates the sprocket that engages with feed holes 422, and carrier tape 41 is transported in the transport direction. Note that cover tape 43 is peeled off over the entire width or a portion thereof from base tape 42 upstream of the component supply position in the tape transport direction.

[0031] As shown in Fig. 4, autoloading feeder 30 has a feeder body 31 provided with a tape transport device 32, a tape feeding device 33, and a supply tape holding device 34. Tape feeding device 33 feeds carrier tape 41 inserted from the rear side (left side in Fig. 4) of feeder body 31 toward the component supply position. Supply tape holding device 34 holds supply carrier tape 41B inserted so as to overlap carrier tape 41A currently in use.

[0032] When the number of components remaining on the carrier tape 41A in use becomes low, the auto-loading feeder 30 feeds and moves the replenishment carrier tape 41B held by the replenishment tape holding device 34 using the tape feeding device 33. When the replenishment carrier tape 41B reaches the component supply position and the opening of the cavity 421 is exposed, the component can be picked up by the suction nozzle 134. In this way, the auto-loading feeder 30 automatically loads the replenishment carrier 41B.

[0033] 4. Method Information M4, Component Supply Method for Feeder 122 Method information M4 indicates the supply method applicable to each type of component supplied to component mounting machine 10 during production of product boards. In this embodiment, as shown in FIG. 7, method information M4 includes various information for each supply method, such as the compatible component type (Pa, Pb, ...) and compatible feeder (normal / ALF). Here, the supply methods include the splicing method (Spl), the standby method (Sta), and the autoloading method (AL).

[0034] 4-1. Splicing Method The splicing method is a supply method in which a supply carrier tape 41, 41B is connected to a carrier tape 41, 41A in use. Specifically, the operator moves the splicing device 57 to the vicinity of a feeder 122 (tape feeder 20) where the remaining number of components has fallen below a predetermined value and is about to run out of components. Then, as shown in FIG. 5, the operator connects the rear end of the carrier tape 41A in use to the front end of the supply carrier tape 41B by applying splicing tape 80 while butting the rear end of the carrier tape 41A in use.

[0035] The splicing tape 80 is composed of, for example, a pair of base tape 81 affixed to the back surface of the carrier tape 41 and cover tape 82 affixed to the front surface. The currently used and replenishment carrier tapes 41A, 41B, connected by the splicing method, maintain the spacing between the cavities 421 and the feed holes 422 at the connection portion, and are transported together by the tape transport device 22. Because the splicing method requires the application of the splicing tape 80, it is not suitable for component types, for example, where the back surface of the carrier tape 41 is significantly uneven, or where the carrier tape 41 is formed of a material that is not suitable for application of the splicing tape 80. Such component types are excluded in advance from the compatible component types.

[0036] The splicing method corresponds to a normal tape feeder 20, and the inventory quantity (Bf11) of the tape feeder 20 is equal to the settable quantity (Bf11). Note that the splicing method includes a method of performing splicing work in which the cutting (length adjustment) of the pair of carrier tapes 41 and the application of the splicing tape 80 are automated using a splicing device 57, as well as a method of manually cutting and applying the splicing tape 80 using a jig that assists in the butt positioning of the pair of carrier tapes 41.

[0037] In the splicing method, the pair of carrier tapes 41A, 41B are fed together, so there is no impact on the cycle time, but low splicing accuracy can affect the feeding of the carrier tape 41 and cause component picking errors. The method information M4 includes evaluation values ​​(VeSp, VeSt, VeAL) that indicate the rate of error occurrence due to switching to the replenishment carrier tape 41, 41B during placement processing. For example, the evaluation value (VeSp) is set in the splicing method column, taking into account the splicing operation execution method and performance (error rate).

[0038] 4-2. Standby Method The standby method is a supply method that uses spare feeder 20B. More specifically, as shown in FIG. 2, the mounting process is performed using tape feeder 20A, which is feeder 122 that supplies components of a predetermined component type. In addition, spare feeder 20B, which is feeder 122 pre-loaded with supply carrier tapes 41, 41B that store components of the same component type as tape feeder 20A, is set in another slot 121. Spare feeder 20B is not used and remains in a standby state while tape feeder 20A is supplying components.

[0039] Then, while the mounting process is being performed, the supply of components is switched from tape feeder 20A to spare feeder 20B, thereby allowing the supply of components to continue. The timing for switching to spare feeder 20B may be when tape feeder 20A runs out of components, or when the number of components remaining in tape feeder 20A falls below a predetermined number. The occurrence of a component shortage is recognized based on the detection value of a sensor provided in component mounting machine 10 or tape feeder 20, the results of image processing of image data acquired by camera imaging, the presence or absence of a sampling error, etc.

[0040] The standby method corresponds to all component types that can be supplied by a normal tape feeder 20. In particular, components that cannot be set to the splicing method or the autoloading method are recorded in the method information M4 as constrained components (Ph, Pn, ...) that are restricted from being supplied by the standby method. Unlike the splicing method, the standby method does not require splicing and can reduce the occurrence of picking errors due to component supply, and the evaluation value (VeSt) is set taking into account the actual results (error rate). However, since the standby method uses multiple tape feeders 20 (20A, 20B), when one tape feeder 20A and one spare feeder 20B are used, half of the feeder inventory (Bf11) is set as the settable number (Bf11 / 2).

[0041] Furthermore, when components are supplied by the spare feeder 20B using the standby system, the movement path of the mounting head 133 during the mounting process changes. In particular, the slot 121 in which a specific feeder 122 (tape feeder 20A) is set is set, for example, by optimization processing, so that the movement distance of the mounting head 133 is as short as possible. Therefore, when components are switched to be supplied from the spare feeder 20B, the time required for the mounting process (cycle time) may increase.

[0042] Therefore, in the standby system, the above factors are taken into consideration when setting the impact (Dt) on the cycle time caused by switching to the replenishment carrier 41B loaded on the spare feeder 20B. The impact on the cycle time may be calculated by simulation as the percentage or specific number of seconds of the cycle time extended by component supply from the spare feeder 20B, or may be an average or approximate value calculated from actual results. Even if the cycle time of a specific placement process is extended by applying the standby system, it may be possible to evaluate that there is no impact on overall production if that placement process does not become a bottleneck process on the production line.

[0043] 4-3. Auto-loading Method The auto-loading method is a replenishment method using an auto-loading feeder 30. The auto-loading feeder 30 automatically loads a replenishment carrier tape 41, 41B when the number of remaining components on the carrier tape 41, 41A in use falls below a predetermined number. In this embodiment, as shown in FIG. 4, the auto-loading feeder 30 inserts the replenishment carrier tape 41B so that it overlaps the carrier tape 41A in use. The replenishment carrier tape 41B is held by a replenishment tape holding device 34 to prevent it from falling off.

[0044] When components are supplied by auto-loading feeder 30 and the rear end of carrier tape 41A in use passes a predetermined position on the tape transport path, replenishment carrier tape 41B is transported and loaded by driving tape feed device 33. As a result, replenishment carrier tape 41B is transported following carrier tape 41A in use, components are replenished, and component supply by auto-loading feeder 30 continues.

[0045] The autoloading method requires a dedicated autoloading feeder 30 (ALF) and is limited to component types (Pa, Pe, ...) compatible with the autoloading feeder 30. Therefore, with the autoloading method, the inventory quantity (Bf12) of the autoloading feeder 30 is equal to the settable quantity (Bf12). Furthermore, unlike the splicing method, the autoloading method does not require splicing, and can reduce the occurrence of picking errors due to component replenishment. The evaluation value (VeAL) is set taking into account actual results (error rate). Furthermore, unlike the standby method, the autoloading method continues component replenishment from the same feeder 122, so there is no impact on cycle time.

[0046] 5. Mounting Assist Device 60 The configuration of the mounting assist device 60 will be described with reference to FIGS. 6 to 10. The mounting assist device 60 supports the production of product boards by the component mounting machines 10. In the production of product boards on the production line Ln, the mounting process executed by each component mounting machine 10 is optimized from the perspective of shortening cycle time and improving uniformity. To maintain efficient productivity, it is useful to prevent unexpected errors from occurring, or to take measures to ensure that even if an error does occur, it does not affect overall production.

[0047] If production on the production line Ln continues and a parts shortage is predicted, the production system Sy can notify workers and prompt them to replenish parts. However, depending on the progress of production, requests for parts replenishment may be concentrated in a certain period, making it impossible to complete the replenishment in time, or errors in the replenishment work may cause some mounting processes to be interrupted. It has been discovered that further optimization can be achieved by configuring the system to take into account the characteristics of the parts replenishment method in order to address such events.

[0048] Therefore, the production support device 60 is configured to appropriately set a replenishment method for components allocated to multiple component placement machines 10 so as to maintain the expected production efficiency. As shown in FIG. 6, the placement support device 60 includes a process design unit 61 and a method setting unit 62. The placement support device 60 may further include a reel setting unit 63. The process design unit 61 executes a process design process (process design step, S10) in the production support process shown in FIG. 10. The method setting unit 62 executes a method setting process (method setting step, S20). The reel setting unit 63 executes a reel setting process (reel setting step, S23) in the method setting step.

[0049] The process design unit 61 executes a process design process for allocating the types and quantities of components to be mounted in the mounting process by the component mounting machines 10 to the component mounting machines 10 (S10). Specifically, the process design unit 61 determines the number of steps in the mounting process in accordance with the number of component mounting machines 10 constituting the production line Ln, based on design information including the types and mounting positions of the components to be mounted on the product board.

[0050] 8 shows an example of the process design processing results. In this embodiment, the process design unit 61 executes the process design processing based on the production plan M1 and the product information M2 so as to improve the uniformity of the cycle times (Cp1, Cp2, ...) required for each mounting process (D1, D2, ...) of the multiple component mounting machines 10 on the production line Ln. This equalizes the cycle times and improves the load balance on the production line Ln.

[0051] However, bottleneck processes occur due to the fact that the distance from the component supply position to the mounting position in the component supply device 12 differs for each component, and that there are restrictions on the speed (or acceleration) of the mounting operation depending on the type of component. The "bottleneck process" mentioned above refers to the mounting process (each process) that has the longest cycle time among the mounting processes (each process) that can be executed simultaneously by multiple component mounting machines 10, as shown in Figure 9. The process design unit 61 may make adjustments so that components that are prone to mounting errors or that are difficult to mount are preferentially transferred in a mounting process other than the bottleneck process.

[0052] Furthermore, when referencing the product information M2, the process design unit 61 may detect that the components required to produce a specific product board include constrained components (Ph, Pn, ...) that are restricted from being supplied using the standby method. Here, the standby method is expected to extend the cycle time by a predetermined amount during the period when component supply is switched to the spare feeder 20B. Therefore, in the process design process, the process design unit 61 may assign component types to multiple component placement machines 10 so that constrained components are placed on the production line Ln using a placement process with a relatively short cycle time (e.g., placement processes Cp2 and Cp6 in FIG. 9 ).

[0053] In the production support process, component types and quantities are assigned to component mounting machines 10, and a component supply method is set. The supply method can be set by, for example, temporarily assigning component types and quantities and setting the supply method, and then adjusting it based on predetermined conditions. Alternatively, component types and quantities are assigned without taking the supply method into account, and then setting the supply method based on predetermined conditions. In this embodiment, the former setting method is used.

[0054] Specifically, in the process design process, the process design unit 61 assigns component types to multiple component mounting machines 10 and provisionally sets the feeders 122 and replenishment methods to be used to supply the components. As a result, as shown in FIG. 8 , a replenishment method (Spl, AL, Sta) is provisionally set for each component type (Pa, Pc, ...) assigned to each mounting process (D1, D2, ...). The provisional replenishment method may be set to prioritize the autoloading method for component types with large quantities, or the standby method for component types with large sizes. Note that the provisional replenishment method, and the changes and settings of the replenishment method described below, are designed to avoid exceeding the settable number based on the inventory number of the feeders 122.

[0055] 5-2. Method Setting Unit 62 Based on the method information M4, the method setting unit 62 executes a method setting process (S20) to set a supply method for each component assigned to the multiple component mounting machines 10. Here, the supply method is provisionally set as an initial value, so in the method setting process, the method setting unit 62 performs a proper evaluation of the provisionally set supply method for each of the multiple components assigned to the component mounting machines 10 based on the method information M4, and changes and sets the supply method based on the result of the proper evaluation.

[0056] Specifically, in the method setting process (S20), the method setting unit 62 first performs an aptitude evaluation (S21). The method setting unit 62 calculates the likelihood of an error occurring, the impact on overall production if an error occurs, and the degree of impact based on the cycle time (Cp1, Cp2, ...) of each placement process (D1, D2, ...), the bottleneck process (D3), the planned number of replenishments (N1a, N1c, ...), the evaluation values ​​(VeSp, VeSt, VeAL) and the cycle time impact (Dt) of the method information M4. Then, the method setting unit 62 calculates the aptitude evaluation values ​​(Va11, Va12, ...) for each component type in each placement process based on the likelihood of an error occurring, etc.

[0057] In other words, the lower the appropriateness evaluation value, the higher the possibility of a sampling error occurring, or the greater the impact on the entire production if a sampling error occurs. On the other hand, the higher the appropriateness evaluation value, the lower the possibility of a sampling error occurring, or the less likely it is that a sampling error will occur even if it does occur, since it is not included in a bottleneck process or a process close to it and will not affect the entire production. The method setting unit 62 determines whether the uniformity of cycle time and the appropriateness evaluation value on the production line Ln satisfy the optimization criteria (S22).

[0058] If at least one of the cycle time uniformity and the appropriateness evaluation value does not satisfy the optimization criterion (S22: No), the method setting unit 62 moves or exchanges component types between different mounting processes, or exchanges the supply method (S24). The method setting unit 62 preferentially sets the splicing method or the autoloading method for components to be mounted by mounting processes with relatively long cycle times (D3 and D5 in FIG. 9) on the production line Ln.

[0059] Specifically, as shown in Figures 8 and 9, the method setting unit 62 exchanges the component types (Ph, Pu) and replenishment methods (Sta, AL) between the two placement processes (D5 and D6). As a result, the autoloading method is set for the placement process (D5) that is close to the bottleneck process (D3), and the standby method is set for the placement process (D6) that has a relatively generous cycle time. In this way, if there is a change in component allocation (S25: Yes), the placement support device 60 recalculates the cycle time (S26). This updates the process design processing results.

[0060] 8 and 9, the method setting unit 62 may also switch the supply method (AL, Spl) between two placement processes (D2 and D3) without switching component types. This allows the autoloading method to be set for the bottleneck process (D3) and the splicing method to be set for the placement process (D2) with a relatively generous cycle time. By changing and setting the supply method in this way, even if a picking error occurs or the cycle time is extended due to the standby method, the impact on overall production is minimized.

[0061] If, for example, only the supply method is changed and no change is made to the allocation of parts (S25: No), the mounting assistance device 60 omits recalculation of the cycle time, etc. (S26). Then, if a component type is moved or replaced, or the supply method is changed (S24), as described above, the suitability evaluation is performed again (S21). The above process is repeated until it is determined that the optimization criteria are met.

[0062] 5-3. Reel Setting Unit 63 If ​​the adequacy evaluation value satisfies the optimization reference value (S22: Yes), the reel setting unit 63 executes the reel setting process (S23). Even when the component type and quantity are set for each mounting process as described above, and a replenishment method is also set, there may be multiple reels 40 in stock that contain the same component type. For new components, the reel size (Rz9, Rz11, ...) correlates with the remaining quantity (nTa1, nTa2, ...). For example, by assigning a reel 40 with a large remaining quantity, even for the same component type, the number of component replenishments may be reduced.

[0063] Therefore, the reel setting unit 63 sets the components, for which a replenishment method has been set, to be supplied from the carrier tape 41 of a specific reel 40, based on inventory information M3 in which the remaining number of components is associated with the identification code (reel ID) of the reel 40. As a result, a reel 40 (Ra1, Rc1, ...) is assigned to each component type, as shown in Figure 8. For example, when there are multiple reels 40 (Pa-Px01, Pa-Px02, ...) that store the same type of components, and the bottleneck process (D3) or a placement process (D5) close to it includes a replenishment method with a relatively low appropriateness evaluation value, the reel setting unit 63 appropriately sets the reel 40.

[0064] Specifically, the reel setting unit 63 prioritizes reels 40 with a large number of remaining components for components set in the splicing method and components supplied by the tape feeder 20A before switching to the spare feeder 20B in the standby method. This minimizes the number of component replenishments during placement processes with relatively long cycle times, such as bottleneck processes. As a result, the possibility of a picking error can be reduced.

[0065] 6. Effects of the Configuration of the Embodiment According to the configuration of the mounting support device 60 exemplified in the embodiment, the supply method (Spl, Sta, AL) is appropriately set for the components allocated to the multiple component placement machines 10 that make up the production line Ln. This helps ensure that production on the production line Ln is carried out within the scheduled cycle time (Cp1, Cp2, ...), thereby maintaining the expected production efficiency.

[0066] 7. Modifications of the Embodiment 7-1. Production Support Processing In the embodiment, the component supply method has been described as being any one of a splicing method, a standby method, and an autoloading method. However, the component supply method may include other methods. For example, the component supply method may include a method in which, when a component runs out, another spare feeder is set in the same slot 121 as a replacement.

[0067] Furthermore, the component supply device 12 may supply components using a supply device other than the tape feeder 20. For example, the component supply device 12 may supply components using a stick feeder, a bulk feeder, or a tray unit. Similarly, the production support device 60 may execute production support processing for these supply devices based on method information M4, which includes information about the component supply method (such as the supported component types and evaluation values).

[0068] In the embodiment, the production support process is configured to provisionally set the supply method in the process design process. However, a method may be adopted in which the supply method is not specified in the process design process, and the supply method is set later based on various information including the method information M4. Even with such a configuration, the same effects as those of the embodiment can be achieved.

[0069] 7-2. Others In the embodiment, the mounting assist device 60 is configured to be incorporated into the host computer 51. However, part or all of the mounting assist device 60 may be incorporated into an external device of the host computer 51. For example, the mounting assist device 60 may be incorporated into the line management device 55, or may be a dedicated device installed on the production line Ln.

[0070] 10: Component mounting machine, 12: Component supply device, 121: Slot, 122: Feeder, 123: Reel holder, 20, 20A: Tape feeder, 20B: Spare feeder, 30: Autoloading feeder, 40: Reel, 41: Carrier tape, 41A: Carrier tape (in use), 41B: Carrier tape (for replacement), 51: Host computer, 55: Line management device, 60: Production support device, 61: Process design unit, 62: Method setting unit, 63: Reel setting unit, Sy: Production system, Ln, Ln1, Ln2: Production line, M1: Production plan, M2: Product information, M3: Inventory information, M4: Method information

Claims

1. A production support device applied to a production line in which a plurality of component mounting machines arranged in a line in the transport direction of a board execute a mounting process to mount components on the board to produce product boards, the production support device comprising: a process design unit that executes a process design process to allocate the types and quantities of components to be mounted in the mounting process by the plurality of component mounting machines to the plurality of component mounting machines; and a method setting unit that executes a method setting process to set a supply method for each of the components allocated to the plurality of component mounting machines based on method information that indicates a supply method applicable to each type of component to be supplied to the component mounting machines during the production of the product boards.

2. The production support device of claim 1, wherein the component mounting machine supplies the components using a feeder that feeds and moves a carrier tape that contains a plurality of the components, and the supply methods include: a splicing method in which the supply carrier tape is connected to the carrier tape in use; a standby method in which a spare feeder that is a feeder pre-loaded with the supply carrier tape is set in the component mounting machine and the supply of components is switched from a predetermined feeder to the spare feeder while the mounting process is being performed; and an auto-loading method in which the supply carrier tape is automatically loaded when the remaining number of components on the carrier tape in use falls below a predetermined number.

3. A production support device according to claim 2, wherein the process design unit executes the process design process so as to increase uniformity in the cycle times required for the respective mounting processes by the multiple component mounting machines on the production line.

4. The production support device described in claim 3, wherein the process design department executes the process design process so as to increase the degree of uniformity based on a production plan indicating the target production number for each product type of product board produced on the production line and product information indicating the type and quantity of the parts required to produce the product board.

5. The production support device described in claim 3 or 4, wherein the method information includes an evaluation value indicating the rate of error occurrence due to switching to the replenishment carrier tape during execution of the mounting process, the degree of impact on the cycle time, and the number that can be set for each of the multiple types of replenishment methods, and the method setting unit executes the method setting process based on the method information.

6. A production support device as claimed in any one of claims 3-4, wherein the method setting unit preferentially sets the splicing method or the autoloading method for the parts to be mounted by the mounting process having a relatively long cycle time on the production line.

7. A production support device as claimed in any one of claims 3-4, wherein, when the components required to produce a specified product board include a constrained component that is restricted from being supplied using the standby method, the process design department, in the process design process, assigns the component types to a plurality of component mounting machines so that the constrained component is mounted on the production line by the mounting process that has a relatively short cycle time.

8. A production support device as described in any one of claims 2-4, further comprising a reel setting unit that sets the component for which the supply method is set to be supplied from the carrier tape of a specified reel based on inventory information in which the remaining number of components contained in the carrier tape is associated with the identification code of the reel on which the carrier tape is wound.

9. The production support device of claim 8, wherein when there are multiple reels containing the same type of parts, the reel setting unit prioritizes the reel with the largest remaining quantity for the parts to which the splicing method is set and the parts supplied by the feeder before switching to the spare feeder in the standby method.

10. A production support device as described in any one of claims 2-4, wherein the process design unit, in the process design processing, assigns the types of components to the multiple component mounting machines and provisionally sets the feeders and supply methods to be used to supply the components, and the method setting unit, in the method setting processing, performs an appropriate evaluation of the provisionally set supply method based on the method information for each of the multiple components assigned to the component mounting machines, and changes and sets the supply method based on the results of the appropriate evaluation.

11. A production support method applied to a production line in which a plurality of component mounting machines arranged in a line in the transport direction of a board perform a mounting process to mount components on the board to produce product boards, comprising: a process design step of performing a process design process to allocate the types and quantities of components to be mounted in the mounting process by the plurality of component mounting machines to the plurality of component mounting machines; and a method setting step of performing a method setting process to set a supply method for each of the components allocated to the plurality of component mounting machines based on method information indicating a supply method applicable to each type of component to be supplied to the component mounting machine during the production of the product boards.

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