Substrate Work Unit Exchange Based on Work Quality Feedback
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Solution Overview
Problem
Existing substrate work systems do not effectively maintain constituent units like tape feeders at optimal times, leading to reduced operating ratios and work quality due to manual intervention and limited maintenance timing.
Innovation Solution
A substrate work system that includes a determination section to assess maintenance needs based on work quality information, a control section to automate the exchange and maintenance of work units, and a conveyance device to facilitate the transfer of units between storage, work devices, and maintenance devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual maintenance of tape feeders is performed at arbitrary timings, then maintenance can be carried out, but the operating ratio is reduced due to production work interruptions
Solution Approach 1:
The system performs preliminary assessment of maintenance needs based on mounting accuracy data before actual maintenance is required. The determination section evaluates whether maintenance is necessary by comparing mounting accuracy against predetermined thresholds, allowing maintenance to be scheduled in advance during natural interruptions rather than responding to quality degradation in real-time
Solution Approach 2:
The system establishes a feedback loop where mounting accuracy information is continuously monitored and fed back to the determination section. This feedback mechanism enables the system to assess maintenance needs based on actual performance data, triggering maintenance only when mounting accuracy deteriorates below acceptable levels, thereby avoiding unnecessary production interruptions
2Productivity
If tape feeders are exchanged automatically at component shortage or setup changeover, then operating ratio is maintained, but maintenance at other timings is not performed
Solution Approach 1:
The system enables self-service by automatically assessing maintenance needs and scheduling exchanges without operator intervention. The determination section autonomously evaluates mounting accuracy data and decides whether maintenance is required, allowing the system to service itself at appropriate timings while maintaining continuous operation
Solution Approach 2:
The system performs preliminary assessment of maintenance needs based on accumulated mounting accuracy data before quality degradation becomes critical. By evaluating performance trends in advance, the system can schedule maintenance during natural production interruptions rather than waiting for failures to occur
3Reliability
If operator determines maintenance timing manually, then maintenance can be performed, but exchange work requires operator intervention reducing efficiency
Solution Approach 1:
The system transfers the maintenance determination function from operators to an automated determination section that evaluates mounting accuracy data objectively. This self-service approach eliminates subjective judgment and manual decision-making, allowing the system to autonomously assess maintenance needs and trigger exchanges without operator involvement
Solution Approach 2:
The system replaces manual operator judgment with automated electronic assessment. The determination section uses predetermined criteria and mounting accuracy data to objectively determine maintenance needs, substituting human decision-making with automated logic that consistently applies maintenance thresholds
Data Source
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AI summary
A substrate work system including a work device configured to perform predetermined work on a substrate by use of an exchangeable work unit includes a storage section configured to store the work unit, a maintenance device configured to perform maintenance of the work unit, a conveyance device capable of conveying the work unit, a determination section configured to determine a maintenance time for the work unit used in the work device based on quality information on work quality of the predetermined work, and a control section configured to, when the determination section determines that a maintenance time arrives, cause the conveyance device, the work device, and the maintenance device to unload the work unit for exchange from the storage section, convey the work unit to the work device for being exchanged with the work unit that has been used up in the work device, and convey the used-up work unit so exchanged to the maintenance device so as to be maintained thereby.