Unit management system and unit management method

Abstract

The present invention involves: acquiring history information pertaining to maintenance of a unit attached to a production device; identifying, on the basis of the history information, a unit in which maintenance has been performed; acquiring actual result information indicating a production actual result of usage of the unit after maintenance, for a plurality of times of maintenance performed on the identified unit; predicting, on the basis of at least one of the history information and the actual result information, a usage limit at which the unit cannot be used for production even if maintenance is performed; and outputting, on the basis of the predicted usage limit, information indicating a unit for which an alternative unit is inferred to be required.

Description

Unit management system and unit management method

[0001] The present disclosure relates to a unit management system and a unit management method for managing units that are replaceably attached to production equipment.

[0002] When a production device equipped with a unit breaks down, repairs to the broken unit or replacement work with other equipment may be required, which may disrupt product production. Therefore, various methods have been proposed to reduce the impact of the breakdown. Patent Document 1 discloses a production management device that includes a failure determination unit that uses sensors to monitor the status of production equipment installed on a product production line to detect signs of a failure, a repair determination unit that calculates a repair method and repair time for the failure, and a recovery plan creation unit that creates a recovery plan (e.g., repair method, repair timing, and production plan change proposal). In the production management device of Patent Document 1, the recovery plan creation unit creates a recovery plan that increases production indices throughout the factory, and improves the production evaluation index of the entire factory by controlling the period during which the broken production equipment cannot be used.

[0003] Japanese Patent No. 7056574

[0004] However, in conventional technologies including Patent Document 1, recovery plans are created on the assumption that failed production equipment or units will always be restored by repair, but there are some units that cannot be restored by repair depending on their usage conditions, etc., and there is room for further improvement in order to appropriately manage units, including units that may not be restored by repair.

[0005] Therefore, an object of the present disclosure is to provide a unit management system and a unit management method that can appropriately manage units that require maintenance.

[0006] The unit management system disclosed herein includes an identification unit that acquires historical information indicating the history of maintenance performed on units that are replaceably attached to production equipment that produces products, and identifies the units on which maintenance was performed; an acquisition unit that acquires performance information indicating the production results using the identified units after multiple maintenances performed on them; a prediction unit that predicts, based on at least one of the historical information and the performance information, the end of use date at which the unit will no longer be usable for production even after maintenance, or the end of use count until the unit will no longer be usable for production even after maintenance; and an output unit that outputs information indicating units that are estimated to require a replacement unit, based on the predicted end of use date or the predicted end of use count.

[0007] The unit management method disclosed herein acquires historical information indicating the history of maintenance performed on units that are replaceably attached to production equipment that produces products, identifies the units for which maintenance was performed based on the historical information, acquires performance information indicating the production results using the identified units after maintenance for multiple maintenance performed on them, predicts the end of use period at which the unit will no longer be usable for production even after maintenance, or the maximum number of uses until the unit will no longer be usable for production even after maintenance, based on at least one of the historical information and the performance information, and outputs information indicating units that are estimated to require a replacement unit based on the predicted end of use period or the maximum number of uses.

[0008] According to the present disclosure, units requiring maintenance can be appropriately managed.

[0009] FIG. 1 is a diagram illustrating the configuration of a mounting system according to an embodiment of the present disclosure; FIG. 2 is a front view illustrating the configuration of a main part of a component mounting device provided in a mounting line according to an embodiment of the present disclosure; FIG. 3 is a block diagram illustrating the configuration of a mounting system according to an embodiment of the present disclosure; FIG. 4 is an explanatory diagram illustrating an example of the configuration of unit information created in a mounting system according to an embodiment of the present disclosure; FIG. 5 is an explanatory diagram illustrating a prediction of the limit number of uses based on sensor values ​​after maintenance in a mounting system according to an embodiment of the present disclosure;

[0010] An embodiment of the present disclosure will be described in detail below with reference to the drawings. The configurations, shapes, and the like described below are merely examples for explanatory purposes and may be modified as appropriate depending on the specifications of the mounting system, mounting line, management computer, component mounting device, and the like. Corresponding elements in all the drawings will be denoted by the same reference numerals, and redundant description will be omitted. In FIG. 1 and in some portions described below, two axes perpendicular to each other in a horizontal plane are shown: an X-axis in the substrate transport direction (the left-right direction in FIG. 1 ), and a Y-axis perpendicular to the substrate transport direction (the up-down direction in FIG. 1 ). In FIG. 2 and in some portions described below, a Z-axis (the up-down direction in FIG. 2 ) is shown as a height direction perpendicular to the horizontal plane.

[0011] First, the configuration of the mounting system 1 will be described with reference to FIG. 1. FIG. 1 is a configuration explanatory diagram of a mounting system according to an embodiment of the present disclosure. The mounting system 1 is configured such that three mounting lines L1 to L3 arranged on a floor F are connected by a wired or wireless communication network 2 and are managed by a management computer 3. As will be described later, each mounting line L1 to L3 is configured by connecting multiple production devices, including a printing device and a component mounting device, and has the function of producing circuit boards (mounted boards) with components mounted on a board. Note that the number of mounting lines L1 to L3 provided in the mounting system 1 does not need to be three; one, two, four or more may be used.

[0012] A maintenance support device 4 is located on floor F, at a position away from mounting lines L1 to L3. The maintenance support device 4 is connected to a management computer 3 via a communication network 2. The maintenance support device 4 has the function of automatically performing maintenance on nozzles, feeders, heads, and the like that are replaceably attached to component mounting devices. The maintenance support device 4 may be located on a different floor or in a different factory from floor F on which mounting lines L1 to L3 are located. Furthermore, the maintenance results may be transmitted from the maintenance support device 4 to the management computer 3 via the communication network 2, or may be transmitted indirectly to the management computer 3 via the Internet or the like.

[0013] Next, the detailed configuration of mounting lines L1 to L3 will be described with reference to Figure 1. Mounting lines L1 to L3 have the same configuration, and below, mounting line L1 will be described. Mounting line L1 is configured by connecting production equipment such as printing device M1, component mounting devices M2 to M5, and reflow device M6 in series, in that order from upstream (left side of the page) to downstream (right side of the page) in the board transport direction. The production equipment is connected to management computer 3 via communication network 2. Note that mounting line L1 is a group of production equipment connected via communication network 2, and the production equipment does not have to be physically connected to each other.

[0014] In Figure 1, printing device M1 has the function of printing paste solder onto a board through a screen mask. Component mounting devices M2 to M5 have the function of picking up components supplied from a feeder using nozzles attached to their heads, transporting them to mounting points on the board where the solder has been printed, and mounting them there. Reflow device M6 has the function of heating the board on which components have been mounted, melting the solder, and then solidifying it to solder the components to the board. In this way, printing device M1, component mounting devices M2 to M5, and reflow device M6 are production devices that have the function of producing circuit boards (products) with components mounted on them.

[0015] The management computer 3 performs processes such as production management of the circuit boards manufactured on the mounting lines L1 to L3, creation of programs and data used by each production device to manufacture the circuit boards, downloading of the programs and data to each production device, etc. The management computer 3 also functions as a maintenance management device that manages maintenance performed on units (nozzles, feeders, heads, cameras, motors, etc.) that are replaceably attached to the component mounting devices M2 to M5.

[0016] Next, the configuration of component mounting devices M2 to M5 will be described with reference to FIG. 2. FIG. 2 is a front view showing the configuration of the main parts of a component mounting device provided in a mounting line according to an embodiment of the present disclosure. A board transport unit 6 is arranged along the X-axis in the center of the base 5. The board transport unit 6 transports a board 7 transported from upstream to a work position, positions it, and holds it. The board transport unit 6 also transports the board 7 downstream after the component mounting work has been completed.

[0017] The board transport unit 6 includes a motor that rotates the conveyor that transports the board 7, a sensor that detects the stopping position of the board 7, and the like. The board transport unit 6 detects transport errors, such as when the transported board 7 does not stop at a predetermined stopping position. During maintenance, the driving state of the motor of the board transport unit 6 and the state of the sensor are adjusted. The motor and sensor of the board transport unit 6 are replaceable units U.

[0018] 2, component supply units 8 are located at the front and rear of each of component mounting devices M2 to M5. Each component supply unit 8 has a carriage 9 with a plurality of feeders 10 pre-installed on a feeder base 9a. The carriage 9 holds a tape reel 12 that stores a wound component tape 11 containing components D. The component tape 11 is pulled out from the tape reel 12 and pitch-fed to the component supply position 10a, thereby supplying the components D to the component supply position 10a.

[0019] The feeder 10 is equipped with a motor for feeding the component tape 11 and a sensor for detecting the position of the component tape 11. The feeder 10 detects supply errors, such as when components D are not supplied to the specified component supply position 10a. During maintenance, the maintenance support device 4 is used to adjust the feeder 10. The feeder 10 is a replaceable unit U.

[0020] 2, a head 14 equipped with a nozzle 13 for holding a component D is disposed above the base 5. The head 14 is moved by a head moving mechanism 15 between the component supply unit 8 and the board 7 held at the work position by the board transport unit 6. This allows the component mounting work to be performed, in which the nozzle 13 picks up a component D from a feeder 10 of the component supply unit 8 and mounts it on a mounting point on the board 7.

[0021] The head 14 is equipped with a motor for raising and lowering the nozzle 13, a sensor for measuring the flow rate of air flowing into the attached nozzle 13, and the like. The head 14 detects suction errors, such as when the nozzle 13 does not properly hold the component D. During maintenance, the nozzle 13 and head 14 are adjusted using the maintenance support device 4. The nozzle 13 and head 14 are replaceable units U.

[0022] The head moving mechanism 15 is an XY robot equipped with a linear drive mechanism that moves the head 14 in a horizontal plane (X-axis direction, Y-axis direction). The head moving mechanism 15 detects stopping errors, in which the moved head 14 does not stop at a predetermined position within a predetermined time, and settling errors, in which vibrations upon reaching the target position do not converge within a predetermined settling time. Furthermore, during maintenance, the drive state of the linear drive mechanism of the head moving mechanism 15 is adjusted. The linear drive mechanism of the head moving mechanism 15 is a replaceable unit U.

[0023] 2, a component recognition camera 16 is disposed between the component supply unit 8 and the board transport unit 6. When the head 14, which has picked up a component D from the feeder 10, moves above the component recognition camera 16, the component recognition camera 16 captures an image of the component D held by the nozzle 13. From the captured image, the holding orientation of the component D is recognized. A head camera 17, which moves integrally with the head 14 by a head movement mechanism 15, is attached above the base 5.

[0024] As head 14 moves, head camera 17 moves above board 7 positioned on board transport section 6 and captures an image of a board mark (not shown) provided on board 7. The image capture result allows the position of board 7 to be recognized. When head 14 mounts components on board 7, the mounting position is corrected taking into account the image capture result of component D by component recognition camera 16 and the image capture result of the board mark by head camera 17.

[0025] The component recognition camera 16 and the head camera 17 each include an imaging unit and an illumination unit that illuminates the imaging target. The component recognition camera 16 and the head camera 17 detect recognition errors that occur when the imaging target is not properly recognized due to a decrease in illuminance of the illumination unit. During maintenance, the state of the optical system and the state of the illumination unit provided in the component recognition camera 16 and the head camera 17 are adjusted. The component recognition camera 16 and the head camera 17 are replaceable units U.

[0026] In this way, the motor and sensor of the board conveying unit 6, the feeder 10, the nozzle 13, the head 14, the linear drive mechanism of the head moving mechanism 15, the component recognition camera 16, and the head camera 17 are a unit U that can be interchangeably attached to the component mounting devices M2 to M5 (production devices) provided on the mounting lines L1 to L3 that produce circuit boards.

[0027] Next, the configuration of the mounting system 1 will be described with reference to FIG. 3. FIG. 3 is a block diagram showing the configuration of a mounting system according to an embodiment of the present disclosure. Here, the configuration related to the function as a unit management system that manages units U (feeder 10, head 14, nozzle 13) that are replaceably attached to component mounting devices M2 to M5 will be mainly described. Mounting lines L1 to L3 have the same configuration, and the following describes mounting line L1. Furthermore, the devices provided on mounting line L1 have the same configuration, and the following describes component mounting device M2.

[0028] 3, component mounting apparatus M2 includes an operation control unit 20, an operation unit 21, an apparatus memory unit 22, a monitoring unit 23, and an apparatus communication unit 24. The operation control unit 20 controls the operation unit 21 based on various data stored in the apparatus memory unit 22, thereby controlling the component mounting operation by component mounting apparatus M2. The operation control unit 20 controls the solder printing operation in printing apparatus M1 and the board heating operation in reflow apparatus M6.

[0029] The monitoring unit 23 monitors production operations using the unit U, such as the supply of components D by the feeder 10 in the component mounting device M2 and the suction of components D by the head 14 and nozzle 13, and notifies the management computer 3 of the operating time, number of uses, output values ​​of sensors possessed by the unit U, etc. The monitoring unit 23 also monitors occurrences of work errors that occur in the component mounting device M2 during the production of circuit boards, and notifies the management computer 3 of the time when the work error occurred, the content of the work error, information identifying the unit U related to the work error, etc. The device communication unit 24 is a communication interface, and sends and receives signals and data to and from other devices and the management computer 3 via the communication network 2.

[0030] 3, the management computer 3 includes a management control unit 30, a management storage unit 31, a collection unit 32, an identification unit 33, an acquisition unit 34, a prediction unit 35, an output unit 36, a display processing unit 37, and a management communication unit 40. The processing units such as the management control unit 30, the collection unit 32, the identification unit 33, the acquisition unit 34, the prediction unit 35, the output unit 36, and the display processing unit 37 are realized by, for example, a memory that stores a control program executed by each processing unit, and a processor that executes the control program.

[0031] The input unit 38 is an input device such as a keyboard, touch panel, or mouse, and each processing unit included in the management computer 3 executes processing in accordance with operation commands and data input from the input unit 38. The display unit 39 is a display device such as a liquid crystal panel, and the display processing unit 37 displays various screens and various information on the display unit 39. The management communication unit 40 is a communication interface, and sends and receives signals and data between the production devices on the mounting lines L1 to L3 and the maintenance support device 4 via the communication network 2.

[0032] 3, the management storage unit 31 is a storage device that stores various types of information. The management storage unit 31 stores information indicating, for example, a production plan and a maintenance plan. The management storage unit 31 is realized by, for example, a flash memory or a hard disk drive (HDD). In addition to component mounting data, the management storage unit 31 stores history information 31a, performance information 31b, unit information 31c, and the like. The unit information 31c stores various types of information related to the units U used in the mounting system 1.

[0033] 3, the collection unit 32 collects information on maintenance performed on the unit U from the maintenance support device 4 and stores it as history information 31a in the management storage unit 31. The collection unit 32 also collects information on maintenance performed by maintenance workers while the unit U is attached to component mounting devices M2 to M5 from an information terminal (not shown) carried by the maintenance worker or the like and stores it as history information 31a.

[0034] The collection unit 32 also collects information on maintenance performed on units U removed from the component mounting devices M2 to M5, and stores the information as history information 31a. The history information 31a stores information identifying the unit U on which maintenance was performed, the date and time the maintenance was performed, the details of the maintenance, and the like.

[0035] In this way, the history information 31a includes information indicating the history of maintenance performed on the units U that are replaceably attached to the component mounting devices M2 to M5 (production devices) that produce circuit boards (products).

[0036] 3, the collection unit 32 collects production results from each production device on the mounting lines L1 to L3 and stores them as performance information 31b in the management storage unit 31. The performance information 31b includes information identifying the units U attached to the component mounting devices M2 to M5, the number of times the units U have been used, the operating time that the component mounting devices M2 to M5, etc. have operated to produce circuit boards, the number of circuit boards produced by the component mounting devices M2 to M5, and information regarding operational errors. Here, the number of times the unit U has been used may be the number of times the unit U has been used in a predetermined period immediately preceding the current time, or the cumulative number of times the unit U has been used up to the current time (hereinafter also referred to as the "total number of times used"). The information regarding operational errors includes the time the operational error occurred, the details of the operational error, and information identifying the unit U related to the operational error.

[0037] In this way, the performance information 31b includes the production performance when the unit U is attached to any of the component mounting devices M2 to M5 (production devices) provided on the multiple mounting lines L1 to L3 and used to produce circuit boards.

[0038] In FIG. 3, the identifying unit 33 acquires the history information 31a and identifies the unit U for which maintenance has been performed based on the date and time of the maintenance included in the history information 31a.

[0039] 3 , the acquiring unit 34 acquires performance information 31b indicating production performance using the unit U after the maintenance for multiple maintenance operations performed on the unit U identified by the identifying unit 33. For example, the acquiring unit 34 acquires information regarding at least one of an operational error that occurred within a predetermined period after the maintenance and an output value of a sensor measured within the above-mentioned predetermined period.

[0040] More specifically, the acquiring unit 34 acquires at least one of the error rate for the unit U for a predetermined period after maintenance (hereinafter referred to as the "error rate R") and the sensor output value for the predetermined period after maintenance (hereinafter referred to as the "sensor value S"). In this way, the error rate R and the sensor value S for the unit U are examples of performance information 31b that indicate the production performance using the unit U after maintenance.

[0041] 3, the acquisition unit 34 further acquires the number of times the unit U has been used in a predetermined period after maintenance (hereinafter also referred to as the actual value of the "number of uses after maintenance"). The number of uses of the unit U after maintenance acquired in this manner is an example of performance information 31b that indicates the production performance using the unit U after maintenance.

[0042] Here, the predetermined period after maintenance is the period from the time when production using the unit U is started after the maintenance of the unit U until the next maintenance is performed. For example, it is a predetermined period such as two days after the unit U is attached to the component mounting device M2 to M5 after the maintenance.

[0043] 3, the prediction unit 35 executes a process for predicting the time when the unit U will no longer be usable for production even after maintenance. For example, the prediction unit 35 predicts a use limit time, which is the time when the unit U will no longer be usable for production even after maintenance, or a use limit count, which is the number of times the unit U can be used before the time when the unit U will no longer be usable for production even after maintenance, based on the history information 31a or the performance information 31b. For example, the use limit time is the time when the number of times the unit U has been used reaches the use limit count.

[0044] Furthermore, the prediction unit 35 predicts the time (predicted replacement time) when it will be necessary to replace the unit U with a substitute unit based on the usage limit time or the usage limit number of times. For example, the substitute unit is a unit of the same type as the unit U.

[0045] Here, the service life limit is either the time when the unit U breaks down, the time when the unit U will not recover to a predetermined state (such as a predetermined sensor value S) even after maintenance, or the time when a predetermined service life limit (estimated service life limit) is reached. Furthermore, the service life limit is either the number of times the unit U can be used before breaking down, the number of times the unit U can be used before it will not recover to a predetermined state (such as a predetermined sensor value S) even after maintenance, or the number of times it can be used before a predetermined number of uses (estimated service life Ct) is reached. Hereinafter, the service life limit or the service life limit will be simply referred to as the "service life limit."

[0046] 3, specifically, the prediction unit 35 predicts the usage limit (time of usage limit, number of usage limit) based on at least one trend of the error rate R for the unit U in a predetermined period after maintenance, the maintenance interval for the unit U, or the number of uses after maintenance for the unit U. For example, the maintenance interval for the unit U is calculated based on at least one of the actual value of the number of uses after maintenance for the unit U included in the performance information 31b and the date and time when maintenance for the unit U was performed included in the history information 31a.

[0047] Furthermore, the actual value of the number of uses of the unit U after maintenance is the number of times the unit U has been used up to the present time, but may also include the number of times the unit U is predicted to be used until production is completed if the use of the unit U continues from the present time onwards to produce circuit boards. More specifically, the actual value of the number of uses of the unit U after maintenance may be calculated by adding the number of times the unit U has been used from the start of production when production began using the unit U after maintenance to the present time, and the remaining number of uses calculated by multiplying the number of components per board mounted using the unit U by the remaining number of boards to be produced.

[0048] Next, the prediction of the usage limit count by the prediction unit 35 will be described with reference to Figures 4 and 5. Figure 4 is an explanatory diagram of an example of the configuration of unit information created in the mounting system according to an embodiment of the present disclosure. Figure 5 is an explanatory diagram of the prediction of the usage limit count based on the sensor value after maintenance in the mounting system according to an embodiment of the present disclosure. The prediction of the usage limit time is realized by the prediction unit 35 performing a process of calculating the usage limit count as well as a process of calculating the time when the usage limit count will be reached.

[0049] 4, the total number of uses C7 is an example of the limit number of uses predicted by the prediction unit 35. The feeder 10 is an example of a unit U.

[0050] 5, at the time when maintenance was performed on feeder 10 whose total number of uses was C4, the sensor value S measured by the sensor of feeder 10 is "S4." The sensor value S "S4" is a value lower than the first sensor threshold value St1. For example, the first sensor threshold value St1 is a threshold value for determining whether maintenance is required for feeder 10. In other words, this means that feeder 10 whose total number of uses was C4 has returned to a normal state as a result of maintenance.

[0051] The prediction unit 35 calculates the number of times that the feeder 10 can be used in production after the total number of uses C4. In other words, the prediction unit 35 calculates "C5 - C4" as the number of times that the feeder 10 can be used in a normal state. Then, if maintenance is performed on the feeder 10 at the total number of uses C5, the prediction unit 35 calculates "C6 - C5" as the number of times that the feeder 10 can be used in a normal state.

[0052] In this way, the prediction unit 35 calculates the number of times the unit U can be used after maintenance (hereinafter also referred to as the predicted value of the "number of uses after maintenance") for multiple maintenances scheduled to be performed on the unit U.

[0053] As described above, the prediction unit 35 calculates the predicted number of uses of the unit U after maintenance, and calculates the limit number of uses. For example, the prediction unit 35 calculates the limit number of uses of the unit U based on the number of times the unit U can be used in a normal state. More specifically, the limit number of uses is calculated by adding the cumulative number of times the unit U has been used up to the present time and the predicted number of uses after maintenance.

[0054] The use limit may be any index that can be generated from the use limit count, and may be, for example, the remaining time from the current point in time until the unit U can no longer be used for production even after maintenance, or the remaining count obtained by subtracting the number of times the unit U has been used up to the current point in time from the use limit count of the unit U. Note that, although an example has been described in Figures 4 and 5 in which the use limit count predicted by the prediction unit 35 is the total use count C7, the use limit count may be any number that is equal to or greater than the total use count C6 and less than the total use count C7.

[0055] 3 , the output unit 36 ​​outputs to the unit information 31c the total number of uses of the identified unit U, the error rate R and sensor value S acquired by the acquisition unit 34, the actual number of uses after maintenance, the usage limit (time to reach usage limit, number of usage limit), and the predicted replacement time predicted by the prediction unit 35. The output unit 36 ​​also outputs to the unit information 31c information indicating the unit U that is estimated to require a replacement unit based on the predicted usage limit (time to reach usage limit, number of usage limit). The output unit 36 ​​also identifies and outputs the units U that will reach their predicted replacement time within a predetermined period based on the predicted replacement time for each unit U.

[0056] 4, an example of unit information 31c for feeder 10 will be described. Unit information 31c includes, for each total number of uses 50 during maintenance, a post-maintenance use count 51, a post-maintenance sensor value 52, a post-maintenance error rate 53, and a predicted replacement time 54. The total number of uses 50 of feeder 10 is the total number of times feeder 10 has supplied component D to component supply position 10a. When the total number of uses 50 is from "0" to "C4," the post-maintenance use count 51, the post-maintenance sensor value 52, and the post-maintenance error rate 53 are actual values. When the total number of uses 50 is from "C5" to "C7," the post-maintenance use count 51, the post-maintenance sensor value 52, and the post-maintenance error rate 53 are predicted values.

[0057] When the total number of uses 50 is "C4" (hereinafter referred to as "total number of uses C4"), the number of uses after maintenance 51 is "C4-C3", the sensor value 52 after maintenance of the sensor equipped in feeder 10 is "S4", and the error rate 53 (defect rate) after maintenance, which is the number of feeding errors by feeder 10 that occurred during a predetermined period after maintenance, is "R4". In addition, the predicted replacement time 54 of feeder 10 at the time of total number of uses C4 is "one year later".

[0058] Next, referring again to Figure 5, a description will be given of a prediction of the limit number of uses based on the actual value of sensor value 52 after maintenance of feeder 10 shown in Figure 4. Figure 5 is an XY graph in which the horizontal axis represents the total number of uses C and the vertical axis represents the sensor value S of the sensor equipped in feeder 10. In this example, a smaller sensor value S indicates a better condition of feeder 10, and a larger sensor value S indicates a worse condition of feeder 10.

[0059] 5, the vertical axis shows the first sensor threshold value St1 and the second sensor threshold value St2. When the sensor value S reaches the first sensor threshold value St1, it is determined whether maintenance is necessary, and a maintenance plan is created so that maintenance of the feeder 10 is performed before the sensor value S exceeds the second sensor threshold value St2. When the sensor value S exceeds the second sensor threshold value St2, the feeder 10 cannot be used for production.

[0060] In this way, the sensor value S is the measurement result of the sensor provided in the unit U. Generally, as the actual number of uses of the unit U after maintenance increases, the state of the unit U transitions in the following order: normal, a premonition state before an abnormal state, and an abnormal state. The sensor value S being less than the first sensor threshold value St1 is an example of the state of the unit U being normal.

[0061] 5 , the sensor value S being equal to or greater than the first sensor threshold value St1 and less than the second sensor threshold value St2 is an example of the state of the unit U being a predictive state. The sensor value S exceeding the second sensor threshold value St2 is an example of the state of the unit U being an abnormal state. In this embodiment, the prediction unit 35 predicts the time when the state of the unit U will not be restored to a normal state even after maintenance. In other words, the prediction unit 35 predicts the limit number of times the unit U can be used before the unit U will not be restored to a normal state even after maintenance.

[0062] 5, straight lines connect the sensor value S0 before use (total number of uses is 0 (zero)), the sensor value before maintenance at total number of uses C1, C2, C3, and C4, and the sensor values ​​S1, S2, S3, and S4 after maintenance (actual values). As the total number of uses C increases, the sensor value S after maintenance tends to gradually deteriorate without recovering to the state it was in at the previous maintenance. Furthermore, the number of uses after maintenance until the sensor value S reaches the first sensor threshold value St1 (51 uses after maintenance) also tends to gradually decrease. In other words, the maintenance interval tends to become shorter.

[0063] Prediction unit 35 predicts the total number of uses C5, C6, C7 at the time of the next maintenance and the sensor values ​​S5, S6, S7 after maintenance based on the number of uses 51 after maintenance (maintenance interval) and the recovery state of sensor value S after maintenance. In this example, it is predicted that when the number of times feeder 10 has been used reaches total number of uses C7, which is less than the expected number of uses Ct, feeder 10 will not be able to recover to a normal state even if it is maintained (see also FIG. 4).

[0064] 4, predicted replacement time 54, which is the time to replace feeder 10 with an alternative unit, is set to the time when the number of times feeder 10 has been used reaches its limit number of uses. In other words, predicted replacement time 54 is set to the time when the limit of use is reached. Note that replacement with an alternative unit is preferably carried out well before the number of times feeder 10 has been used reaches total number of uses C7, and predicted replacement time 54 may also be set to the time when total number of uses reaches C5 or C6. Furthermore, predicted replacement time 54 may also be set to a time period when feeder 10 is not used for production, based on a production plan.

[0065] In FIG. 3, the display processing unit 37 causes the display unit 39 to display a unit replacement information display screen that displays information about the unit U that needs to be replaced within a predetermined period, based on the unit information 31c.

[0066] Next, an example of a unit replacement information display screen 60 displayed on the display unit 39 by the display processing unit 37 will be described with reference to FIG. 6 . FIG. 6 is an explanatory diagram showing an example of a unit replacement information display screen displayed on a display unit provided in a management computer according to an embodiment of the present disclosure. The unit replacement information display screen 60 has a unit name selection frame 61, a replacement time selection frame 62, and a unit information display frame 63. In the unit name selection frame 61, the type of unit U to be displayed in the unit information display frame 63 is selected by operating the input unit 38. In this example, "feeder" is selected. In the replacement time selection frame 62, the replacement time of the unit U to be displayed in the unit information display frame 63 is selected by operating the input unit 38. In this example, "within 6 months" is selected.

[0067] The unit information display frame 63 displays the unit name selected in the unit name selection frame 61 and information about the unit U that matches the replacement date selected in the replacement date selection frame 62. In this example, the unit number, start date of use, predicted failure date, and replacement date of the "feeder due for replacement within six months" are displayed. The unit number is information that identifies the unit U. The start date of use is the date when the unit U started to be used in production. The predicted failure date is the date when it is predicted that the unit U will fail. The replacement date is the predicted replacement date 54 included in the unit information 31c.

[0068] The production manager can easily know the timing for replacing the units U based on the information displayed on the unit replacement information display screen 60, and can purchase the necessary units U at the appropriate time. This makes it possible to prevent production stoppages due to unit U failures and to prevent excessive inventory of units U.

[0069] Next, a unit management method for a unit U replaceably attached to a production device by the mounting system 1 (unit management system) will be described with reference to the flow chart of Fig. 7. Fig. 7 is a flow chart of the unit management method according to an embodiment of the present disclosure. The collection unit 32 appropriately collects history information 31a from the maintenance support device 4, and also collects production results from each production device on the mounting lines L1 to L3, and stores the results in the management storage unit 31 as performance information 31b.

[0070] First, the identifying unit 33 determines whether the collection unit 32 has updated the history information 31a, i.e., whether maintenance has been performed on the unit U (ST1: determination step). When maintenance has been performed (Yes in ST1), the identifying unit 33 acquires history information 31a indicating the history of maintenance performed on the unit U (ST2: history information acquisition step). Next, the identifying unit 33 identifies the unit U on which maintenance was performed based on the acquired history information 31a (ST3: identification step). Next, the acquisition unit 34 acquires performance information 31b indicating production performance using the unit U after maintenance, for multiple maintenance operations performed on the identified unit U (ST4: performance information acquisition step).

[0071] 7, the prediction unit 35 next predicts, based on the history information 31a or the performance information 31b, the use limit time when the unit U will no longer be usable for production even after maintenance, or the limit number of uses until the unit will no longer be usable for production even after maintenance (ST5: use limit prediction step). Next, the output unit 36 ​​outputs information (such as predicted replacement time 54) indicating the unit U that is estimated to require a replacement unit to the unit information 31c based on the predicted use limit (use limit time, limit number of uses) (ST6: output step). This makes it easy to know which unit U will require a replacement unit and when to replace it, and allows appropriate management of the unit U that requires maintenance.

[0072] As described above, the management computer 3 of this embodiment is a unit management system that includes an identification unit 33 that acquires maintenance history information 31a and identifies the unit U for which maintenance was performed; an acquisition unit 34 that acquires performance information 31b that indicates the production performance using the unit U after maintenance for multiple maintenance operations performed on the identified unit U; a prediction unit 35 that predicts the usage limit (time when the unit U will be used until it reaches its limit, the number of times the unit U will be used until it can no longer be used for production even after maintenance) based on at least one of the history information 31a and the performance information 31b; and an output unit 36 ​​that outputs information (unit information 31c) that indicates the unit U that is estimated to require a substitute unit based on the predicted usage limit.

[0073] This allows the units U requiring maintenance to be managed appropriately.

[0074] In the unit management system described above, the management computer 3 is configured to have all the functions of the storage unit and processing unit, but the unit management system is not limited to this configuration. For example, the unit management system may be configured to have a line management computer for each of the mounting lines L1 to L3, the line management computer having a collection unit 32 that collects performance information 31b including the error rate R from the production equipment. Also, the identification unit 33, acquisition unit 34, and prediction unit 35 may be configured to be located on a computer different from the management computer 3. Furthermore, all or some of the functions of the management computer 3 may be implemented on the cloud.

[0075] The maintenance support device 4 may also be configured to acquire a sensor value S measured by a sensor included in the unit U as performance information 31b and transmit it to the management computer 3. Furthermore, the management computer 3 may be configured such that the prediction unit 35 predicts the end of use time or the limit number of uses based on the sensor value S related to the unit U after a predetermined period of time has elapsed since maintenance.

[0076] In addition, in the present embodiment, an example has been described in which the performance information 31b includes the measurement results (sensor values ​​S) of the sensors provided in the unit U, but the performance information 31b may also include status information that indicates the state of the unit U determined based on the measurement results. For example, the state of the unit U may be a state in which the performance of the unit U is deteriorating, a normal state of the unit U, a premonition state before the unit U becomes abnormal, or an abnormal state of the unit U.

[0077] Furthermore, in the present embodiment, an example has been described in which the prediction unit 35 predicts the service limit based on the sensor value S measuring the unit U, but the prediction unit 35 may predict the service limit based on status information of the unit U in addition to or instead of the sensor value S measuring the unit U. For example, in a case where maintenance is performed on the unit U before the state of the unit U becomes abnormal, the prediction unit 35 may predict, as the service limit, the time or number of times the state of the unit U will become abnormal even after maintenance.

[0078] In addition, in the present embodiment, the predicted value of the number of uses after maintenance has been described as the number of times the unit U can be used when the sensor value S is lower than the first sensor threshold value St1, but it may also be the number of times the unit U can be used when the sensor value S is lower than the second sensor threshold value St2. In other words, the prediction unit 35 may predict the usage limit of the unit U by calculating the number of times the unit U can be used in a predictive state.

[0079] Furthermore, in the present embodiment, the prediction unit 35 has been described as an example of predicting the usage limit based on the number of times the unit U is used after maintenance, but the usage limit may also be predicted based on the amount of time the unit U has been used for production in a specified period after maintenance.

[0080] Furthermore, the prediction unit 35 may predict the usage limit based on the actual value of the number of times the unit U has been used for each state of the unit U. In other words, the actual value of the number of times the unit U has been used after maintenance may include the number of times the unit U has been used in a normal state during a predetermined period after maintenance and / or the number of times the unit U has been used in a warning state after maintenance.

[0081] In addition, in this embodiment, an example has been described in which the sensor value S is measured using a sensor possessed by the unit U, but the sensor may also be provided in at least one of the production equipment to which the unit U is attached and a maintenance support device for performing maintenance on the unit U.

[0082] In addition, in the above description, component mounting devices M2-M5 used on mounting lines L1-L3 that produce circuit boards (products) are used as an example of the production devices to which unit U is attached, but the production devices are not limited to this. For example, the production devices may be the printing device M1, reflow device M6, inspection device, etc., provided on mounting lines L1-L3. In this case, although an example has been described in which management computer 3 of the present embodiment acquires performance information 31b for component mounting devices M2-M5, performance information 31b may also be acquired for production devices that are not mounting devices that make up mounting lines L1-L3.

[0083] Furthermore, the production device may be a production device provided in a semiconductor production line that manufactures semiconductor products, a production device provided in an assembly production line that assembles workpieces such as electrical machinery and equipment, general machinery and equipment, or a production device provided in a food processing line that produces processed food products.

[0084] This application is based on a Japanese patent application (Patent Application No. 2024-056937) filed on March 29, 2024, the contents of which are incorporated herein by reference.

[0085] The unit management system and unit management method disclosed herein have the effect of being able to appropriately manage units that require maintenance, and are useful in the field of mounting components on boards.

[0086] 1 Mounting system (unit management system) 3 Management computer (unit management device) L1 to L3 Mounting line M2 to M5 Component mounting device (production device) 10 Feeder (unit) 13 Nozzle (unit) 14 Head (unit) 16 Component recognition camera (unit) 17 Head camera (unit) U Unit R Miss rate S, S0 to S7 Sensor value (measurement result)

Claims

1. A unit management system comprising: an identification unit that acquires history information indicating the history of maintenance performed on units that are replaceably attached to production equipment that produces products, and identifies the units on which maintenance has been performed; an acquisition unit that acquires performance information indicating the production results using the identified units after multiple maintenances have been performed on them; a prediction unit that predicts, based on at least one of the history information and the performance information, the end of use date at which the unit will no longer be usable for production even after maintenance, or the limit number of uses until the unit will no longer be usable for production even after maintenance; and an output unit that outputs information indicating units that are estimated to require a replacement unit, based on the predicted end of use date or the limit number of uses.

2. The unit management system of claim 1, wherein the time to reach the end of use is either the time when the unit breaks down, the time when the unit cannot be restored to a specified condition even after maintenance, or the time when a predetermined expiration date is reached.

3. The unit management system of claim 1, wherein the limit number of uses is either the number of times the unit can be used before it breaks down, the number of times the unit can be used before maintenance no longer restores it to a specified state, or the number of times it can be used until a predetermined number of uses is reached.

4. The unit management system of claim 1, wherein the prediction unit predicts the end of use time or the limit number of uses based on trends in at least one of the production results for a predetermined period after maintenance, the interval between maintenances of the unit, and the number of uses of the unit between maintenances.

5. A unit management system as described in claim 1, wherein the performance information includes information regarding the error rate for the unit, measurement results of a sensor installed in the unit, or an abnormality level indicating an abnormal state or a predictive state of an abnormality for the unit determined based on the measurement results.

6. The unit management system according to claim 1, wherein the unit is at least one of a nozzle, a feeder, and a head attached to a production device provided in a mounting line that produces circuit boards, and the performance information includes production performance when the unit is attached to any of the production devices provided in a plurality of the mounting lines and used to produce circuit boards.

7. A unit management method comprising: acquiring historical information indicating the history of maintenance performed on a unit that is replaceably attached to production equipment that produces products; identifying the unit on which maintenance was performed based on the historical information; acquiring performance information indicating the production results using the identified unit after multiple maintenances performed on the unit; predicting, based on at least one of the historical information and the performance information, the end of use period at which the unit can no longer be used in production even after maintenance, or the maximum number of uses until the unit can no longer be used in production even after maintenance; and outputting information indicating units that are estimated to require a replacement unit based on the predicted end of use period or the maximum number of uses.

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