JP7645482B2 - Management device and management method - Google Patents

Description

This disclosure relates to a management device and a management method.

Patent Document 1 describes a method for diagnosing faults in an electronic component mounter, which includes a first step of notifying a fault diagnosis device of a stopped state of an electronic component mounter that picks up electronic components and mounts them in a predetermined position when the electronic component mounter stops, a second step of monitoring and querying the electronic component mounter for necessary information from the contents of the notification, a third step of deriving and displaying the location of the abnormality and a recovery method from the monitoring information obtained in the second step, and a fourth step of implementing the recovery method obtained in the third step on the electronic component mounter using a communication means.

Japanese Unexamined Patent Publication No. 2-167639

This disclosure provides a management device and a management method that can grasp the current state of a manufacturing device and the state before an abnormality occurred by constantly monitoring and accumulating the internal and external conditions of the manufacturing device using a monitoring device attached to the manufacturing device.

The present disclosure provides a management device for managing a plurality of manufacturing apparatuses arranged on a factory floor, the management device comprising: a monitoring information acquisition unit that acquires monitoring information from a plurality of monitoring devices including one or more first monitoring devices arranged around the plurality of manufacturing apparatuses for monitoring a status of the factory floor and one or more second monitoring devices arranged inside each of the plurality of manufacturing apparatuses for monitoring a status of the manufacturing apparatus; an event information acquisition unit that acquires event information including an occurrence time of an event that occurred in the plurality of manufacturing apparatuses from the plurality of manufacturing apparatuses; a memory unit that stores the monitoring information and the event information; an input unit that accepts a selection of an event recorded in the event information; and an output unit that reads from the memory unit a plurality of pieces of monitoring information acquired from the first monitoring devices and the second monitoring devices for each of the plurality of manufacturing apparatuses for a predetermined period including the occurrence time of the selected event, and outputs a list of the plurality of pieces of monitoring information.

The present disclosure also provides a method for managing a plurality of manufacturing equipment arranged on a factory floor by a management device, the management method comprising the steps of: acquiring monitoring information from a plurality of monitoring devices including one or more first monitoring devices arranged around the plurality of manufacturing equipment for monitoring a status of the factory floor and one or more second monitoring devices arranged inside each of the plurality of manufacturing equipment for monitoring a status of the manufacturing equipment; acquiring event information from the plurality of manufacturing equipment, the event information including an occurrence time of an event that occurred in the plurality of manufacturing equipment; storing the monitoring information and the event information; accepting a selection of an event recorded in the event information; and outputting a plurality of pieces of monitoring information acquired from the first monitoring device and each of the second monitoring devices for each of the plurality of manufacturing equipment for a predetermined period including the occurrence time of the selected event.

This disclosure makes it possible to understand the current state of the manufacturing equipment and the state before the abnormality occurred.

A conceptual diagram showing a factory floor FL on which a plurality of manufacturing devices EQ are arranged. A conceptual diagram illustrating manufacturing equipment EQ arranged on a factory floor FL. FIG. 1 is a system block diagram showing a configuration example of a monitoring system including a plurality of manufacturing devices EQ and a management device 3 according to an embodiment. FIG. 1 is a conceptual diagram showing an example of a format of information indicating a correspondence relationship between a manufacturing device EQ and a monitoring device, the information being stored in a setting information storage unit 39 of a management device 3 according to an embodiment; FIG. 13 is a diagram showing an example of an output by an output unit 33 of a management device 3 according to an embodiment; FIG. 1 is a diagram showing an event list according to an embodiment.

(Background to this disclosure)
When some kind of abnormality (error event) occurs in a manufacturing device, it is conceivable to collect information related to the error and attempt to resolve the error. However, it has been difficult to grasp what factor caused the abnormality. In addition, when an abnormality occurs in a manufacturing device, an operator has to directly operate the manufacturing device and investigate the cause of the abnormality. While the operator is conducting the investigation, product manufacturing by the manufacturing device is stopped. This reduces the production efficiency of the product, and also increases the manufacturing cost since an operator has to be stationed or dispatched to the factory floor where the manufacturing device is located.

Therefore, in the following embodiment, information is collected from multiple monitoring devices that monitor the status of multiple manufacturing equipment arranged on the factory floor, and stored in a management device. Then, the causes of various events, including abnormalities in the manufacturing equipment, can be identified remotely without having to dispatch workers to the factory floor.

Below, with reference to the drawings as appropriate, an embodiment that specifically discloses a management device and a management method according to the present disclosure will be described in detail. However, more detailed explanation than necessary may be omitted. For example, detailed explanations of already well-known matters and duplicate explanations of substantially identical configurations may be omitted. This is to avoid the following explanation becoming unnecessarily redundant and to facilitate understanding by those skilled in the art. Note that the attached drawings and the following explanation are provided to enable those skilled in the art to fully understand the present disclosure, and are not intended to limit the subject matter described in the claims.

Figure 1 is a conceptual diagram showing a factory floor FL on which multiple manufacturing devices EQ are arranged. Multiple manufacturing devices EQ, which may be, for example, chip mounters (mounting machines), are arranged on the factory floor FL (EQ1 to EQ6). An aisle PA is provided on the factory floor FL, along which workers WKR and self-propelled transport robots (not shown) move. The workers WKR operate the manufacturing devices EQ via a means such as a touch panel. The workers WKR perform various tasks on the factory floor FL, such as replacing a tape feeder that supplies a tape containing electronic chips (hereinafter simply referred to as "chips"). The workers WKR or the transport robot move around the factory floor FL to transport replacement parts used by the manufacturing devices.

In this example, six pieces of manufacturing equipment EQ1 to EQ6 are arranged on the factory floor FL. Three pieces of manufacturing equipment EQ1 to EQ3 make up a first row of manufacturing equipment, and three pieces of manufacturing equipment EQ4 to EQ6 make up a second row of manufacturing equipment. For example, an aisle PA is provided between the first row of manufacturing equipment and the second row of manufacturing equipment. This arrangement of multiple pieces of manufacturing equipment EQ on the factory floor FL is merely one example, and the manufacturing equipment EQ and the aisle PA can be arranged on the factory floor FL in various layouts.

As an example of a monitoring device for monitoring the inside of the factory floor FL, cameras CAM1 to CAM10 are attached, for example, to the ceiling of the factory floor FL. A monitoring device is an apparatus that monitors an object such as manufacturing equipment EQ and acquires monitoring information (sensor information) periodically or constantly. For example, if the monitoring device is a camera, the image data (still image or video) captured by the camera is the monitoring information (sensor information). If the monitoring device is a microphone, the audio data recorded by the microphone is the monitoring information. If the monitoring device is a flow sensor, pressure sensor, thermometer, power meter, etc., the flow value, pressure value, temperature value, power value, etc. measured by these devices are the monitoring information. As will be described later, this monitoring information is collected and stored by the management device 3 (see FIG. 3) and used to identify the cause of various events (such as the occurrence of abnormalities) that occur in the manufacturing equipment EQ.

The illustrated arrangement of cameras CAM1 to CAM10 is one example, and the cameras may be arranged in other layouts on the factory floor FL. Cameras CAM1 to CAM6 are each mounted in a position that allows them to image one piece of manufacturing equipment EQ from the front or from diagonally above, with camera CAM1 imaging manufacturing equipment EQ1, camera CAM2 imaging manufacturing equipment EQ2, ... and camera CAM6 imaging manufacturing equipment EQ6. Cameras CAM1 to CAM6 may each be positioned in a position that allows them to image a user interface (described below) such as a touch panel equipped on manufacturing equipment EQ1 to EQ6.

Camera CAM7-CAM10 are each positioned so that they can capture the aisle PA between the manufacturing equipment EQ and the manufacturing equipment EQ facing the aisle PA. For example, camera CAM7 is positioned so that it can capture an image of the first manufacturing equipment row consisting of the manufacturing equipment EQ1-EQ3 from the right side. Camera CAM8 is positioned so that it can capture an image of the first manufacturing equipment row from the left side. Camera CAM9 is positioned so that it can capture an image of the second manufacturing equipment row consisting of the manufacturing equipment EQ4-EQ6 from the right side. Camera CAM10 is positioned so that it can capture an image of the second manufacturing equipment row from the left side. For example, by arranging cameras CAM7-CAM10 in the above positions, it is possible to capture images of the situation around the manufacturing equipment EQ, the situation between adjacent manufacturing equipment EQ, the behavior of workers WKR and transport robots around the manufacturing equipment EQ, etc.

Each of the cameras CAM1 to CAM10, which are an example of a monitoring device, can communicate with other devices via a base station BS1 or the like installed on the factory floor FL. Specific examples of the other devices may be various devices installed in the factory floor FL (including the management device 3 when installed on the same factory floor FL), or various devices installed in a location different from the factory floor FL (for example, a monitoring room MR located away from the factory floor FL) (for example, the management device 3 installed in the monitoring room MR). In this example, information communication is performed by wireless communication using the IP protocol between the cameras CAM1 to CAM10, which are an example of a monitoring device installed on the factory floor FL, and the management device 3 installed in the monitoring room MR. However, information communication may be performed between each device by connecting them by wire. In order to perform information communication, each of the monitoring devices CAM1 to CAM10 is assigned an individual identifier. The individual identifier may be the ID, MAC address, IP address, or the like of the monitoring device, but other identifiers may be assigned to the monitoring devices.

Figure 2 is a conceptual diagram illustrating manufacturing equipment EQ arranged on the factory floor FL. The manufacturing equipment EQ is arranged in a factory and is equipment for manufacturing various products. The manufacturing equipment EQ may be, for example, a solder printing device, a print inspection device, a component mounting device, a mounting inspection device, a reflow device, etc., but may also be other devices.

The manufacturing equipment EQ has a manufacturing equipment main body 1. The manufacturing equipment main body 1 is equipped with a control unit 11 and a user interface 12. The control unit 11 is arranged in the manufacturing equipment main body 1, and is connected to the information management device MGR (described later) via a communication line (not shown) (see FIG. 3). The user interface 12 is typically a touch panel. The user interface 12 accepts operation input of the manufacturing equipment EQ by the worker WKR, and outputs (displays, etc.) information to the worker WKR. However, the user interface 12 is not limited to a touch panel, and may be composed of control buttons, levers, monitors, speakers, etc., either alone or in combination.

The internal device camera 21, which is an example of a monitoring device, is placed in a position where it can capture an image of the inside of the manufacturing device main body 1, and captures an image of the inside of the manufacturing device main body 1. For example, if the manufacturing device EQ is a component mounting device such as a chip mounter, it may capture an image of the area near the tip of the suction nozzle used when mounting chips on a board, or the chip supply position where the chips are supplied. The subject that the internal device camera 21 captures is not limited to this, and it may be placed in a position where it can capture an image of places in the manufacturing device EQ where various errors are likely to occur.

The worker camera 22, which is an example of a monitoring device, captures the appearance and facial expression of the worker WKR who operates the manufacturing equipment EQ. The worker camera 22 may additionally have a face recognition function, an iris recognition function, etc. The worker WKR operates the manufacturing equipment EQ via the user interface 12. Therefore, the worker camera 22 may be disposed near the user interface 12. The worker camera 22 may be integrated with the touch panel or the like that is the user interface 12. The worker camera 22 may capture an image of a person approaching the manufacturing equipment EQ other than the operator.

The microphone 23, which is an example of a monitoring device, captures the voice of the worker WKR who operates the manufacturing equipment EQ and sounds generated near the worker WKR. Like the worker camera 22, the microphone 23 may be placed near the user interface 12. The microphone 23 may also be integrated with the touch panel or the like that is the user interface 12. In addition, as a monitoring device, an internal microphone that captures sounds generated inside the manufacturing equipment EQ may be placed inside the manufacturing equipment EQ. Furthermore, as a monitoring device, a floor microphone that captures sounds inside the factory floor FL may be placed on the walls, ceiling, etc. of the factory floor FL.

The above-mentioned internal camera 21, worker camera 22, and microphone 23, which are examples of monitoring devices, may each be built into the manufacturing equipment EQ in advance, or may be attached to the manufacturing equipment EQ later. The above-mentioned internal camera 21, worker camera 22, and microphone 23, which are examples of monitoring devices, may each be assigned an individual identifier. The individual identifier may be the monitoring device ID, MAC address, IP address, etc., but may also be assigned an identifier other than these. The floor microphone may be attached to the factory floor FL, and may be assigned an identifier similar to the above.

FIG. 3 is a system block diagram showing an example configuration of a monitoring system including multiple manufacturing devices EQ and a management device 3 according to an embodiment. In the illustrated example configuration, the management device 3 is located in a monitoring room MR, which is in a location different from the factory floor FL. However, the management device 3 and the information management device MGR may be located on the factory floor FL.

First, an example of the system configuration on the factory floor FL side will be described. The same components as those in FIG. 2 will be assigned the same reference numerals, and their explanations will be simplified or omitted, with differences being described below. On the factory floor FL, multiple manufacturing devices EQ are arranged (see FIG. 1). The manufacturing devices EQ are equipped with a manufacturing device main body 1 (see FIG. 2). The manufacturing device main body 1 is equipped with a control unit 11, a user interface 12, a working unit 13, a flow sensor 14, and a pressure sensor 15. Note that the flow sensor 14 and the pressure sensor 15 are only examples, and the manufacturing device main body 1 may be equipped with various other sensors. Various monitoring devices 2 are attached to the manufacturing device EQ. However, the monitoring devices 2 may be built into the manufacturing device main body 1 from the beginning.

The control unit 11 controls the user interface 12, the working unit 13, the flow sensor 14, and the pressure sensor 15. The control unit 11 is configured using, for example, a CPU (Central Processing Unit) or an FPGA (Field Programmable Gate Array), and performs various processes and controls in cooperation with a memory (not shown). Specifically, the control unit 11 refers to a program stored in the memory and executes the program to functionally realize the log collection unit 111. The control unit 11 may also control various monitoring devices 2.

The log collection unit 111 collects (or accumulates) event information indicating an event that has occurred in the manufacturing equipment EQ, and transmits the event information to the information management device MGR via the communication line LI. The event information may be transmitted from the log collection unit 111 to the information management device MGR periodically, for example, every three minutes, or may be transmitted when a predetermined amount of data has accumulated in the log collection unit 111. The event information includes information indicating the content of the event that has occurred in the manufacturing equipment EQ and information indicating the time when the event occurred. For example, when the manufacturing equipment EQ is a chip mounter and an event (error event) of "suction error" (an error that the suction nozzle is not properly suctioning the chip) occurs, the log collection unit 111 may accumulate event information including an error ID (event ID) indicating the suction error and the time when the suction error occurred. The format of the event information is not limited to the above.

The content of the event indicated by the event information is not limited to an error (error event) of the manufacturing equipment EQ. For example, the content of the event may be "operation start by operator" indicating that an operator has started operating the manufacturing equipment EQ via the user interface 12. The content of the event may also be an event detectable by the manufacturing equipment EQ, such as a change in the production lot of parts consumed by the manufacturing equipment EQ, refilling of consumables, opening and closing of a door, or removal and installation of an auxiliary unit. When the content of the event is "operation start by operator," the event information may include ID information of the manufacturing equipment EQ (e.g., one of the character strings EQ1 to EQ6, etc.), an event ID indicating an operation start event, and the time when the operator started operating the manufacturing equipment EQ. The content of the event may be "the setting value for operating the manufacturing equipment EQ has been changed by the operator," and in this case, the event information may include ID information of the manufacturing equipment EQ (e.g., one of the character strings EQ1 to EQ6, etc.), an event ID indicating a setting value change event, and the time when the change in the setting value was accepted by the manufacturing equipment EQ. The content of the event may be "an instruction to start operation of manufacturing equipment EQ has been given by an operator," in which case the event information may include ID information of the manufacturing equipment (e.g., one of the character strings EQ1 to EQ6), an event ID indicating an operation start instruction event, and the time when the operation start instruction was received by the manufacturing equipment EQ.

The user interface 12 is similar to that described with reference to FIG. 2, so a detailed description is omitted here.

The working unit 13 is a functional block that performs manufacturing work when the manufacturing equipment EQ manufactures a product. For example, if the manufacturing equipment EQ is a chip mounter, the working unit 13 includes a mounting head equipped with a suction nozzle that mounts chips on a board, a board transport unit that transports the board, a component recognition unit that checks the chips picked up by the suction nozzle by image recognition, a board recognition unit that recognizes the board on which the chips are to be mounted, a component supply unit (feeder) that provides chips to the suction nozzle, etc. However, functional blocks other than these may also be included in the working unit 13.

The manufacturing equipment EQ incorporates a number of sensors for control by the control unit 11 and event detection. The flow rate sensor 14 and pressure sensor 15 are examples of some of these sensors. When the manufacturing equipment EQ is a chip mounter, the flow rate sensor 14 is a sensor that detects the flow rate of air flowing through the suction nozzle. When the suction nozzle successfully picks up a chip, the flow rate of air flowing in from the suction nozzle decreases, but when suction fails, the air flow rate increases. Therefore, a "suction failure" can be detected by the flow rate value acquired by the flow rate sensor 14. When the manufacturing equipment EQ is a chip mounter, the pressure sensor 15 is a load cell that detects the load acting on the suction nozzle. The control unit 11 can detect the load with the load cell and control the height and pressing force of the suction nozzle. These flow rate sensor 14 and pressure sensor 15 can also correspond to monitoring devices.

The monitoring device 2 is a device that acquires various monitoring information such as images and sounds inside and outside the manufacturing equipment EQ and transmits it to the management device 3. Examples of the monitoring device 2 include the internal equipment camera 21, the worker camera 22, the microphone 23, the thermometer 24, and the power meter 25. These monitoring devices may be attached to the manufacturing equipment EQ later, and can transmit acquired information (monitoring information) such as images, sounds, temperature values, and power values to the management device 3 via the base stations BS1 and BS2. Note that when the monitoring device 2 is built into the manufacturing equipment EQ from the beginning, or when the monitoring device 2 is connected to the control unit 11, the various monitoring information acquired by the monitoring device 2 may be accumulated in the log collection unit 111 in the same way as the above-mentioned event information, and transmitted to the management device 3 via the communication line LI.

Each monitoring device 2 may be assigned an individual identifier. The individual identifier may typically be the monitoring device ID, MAC address, IP address (source IP address), etc., but may be an identifier other than these.

As described with reference to FIG. 2, the internal camera 21 captures images of the inside of the manufacturing apparatus main body 1 as monitoring information. More specifically, the internal camera 21 captures images of predetermined locations in each device included in the working unit 13. The worker camera 22 and microphone 23 have the same configuration as those described with reference to FIG. 2, so their description will be omitted here.

When the thermometer 24 is installed outside, it acquires the temperature outside the manufacturing equipment EQ (ambient temperature). When the thermometer 24 is installed inside, it acquires the temperature inside the manufacturing equipment EQ, particularly the temperature of the working section 13 (e.g., the drivers for each axis, the motors for each axis, the controller, the heat sources such as heaters, etc.). The power meter 25 is placed at the input end of the manufacturing equipment EQ, etc., and measures the power consumed per unit time by the manufacturing equipment EQ. When the power meter 25 is placed inside the manufacturing equipment EQ, it measures the power consumed per unit time by electrical equipment such as the drivers for each axis, the controller, and the heaters. In addition, various sensors such as a hygrometer and an object detection sensor may be placed inside and outside the manufacturing equipment EQ to acquire monitoring information.

The communication line LI communicatively connects the manufacturing equipment EQ to other equipment on the network (e.g., another manufacturing equipment). The communication line LI may communicatively connect equipment in the factory floor FL to equipment in the monitoring room MR (e.g., the information management device MGR described below). The communication line LI may be a dedicated line or a shared wired line. The communication line LI may communicatively connect the equipment in the factory floor FL to the equipment in the monitoring room MR via the Internet.

Next, an example of the system configuration on the monitoring room MR side in FIG. 3 will be described. The monitoring room MR is equipped with an information management device MGR and a management device 3 according to the embodiment.

The information management device MGR consolidates and manages various information (such as event information and monitoring information) transmitted from multiple manufacturing devices EQ arranged on the factory floor FL. The information management device MGR may transmit a control signal for remotely controlling the manufacturing devices EQ to each of the manufacturing devices EQ. The information management device MGR transmits the above-mentioned event information and monitoring information received from the manufacturing devices EQ to the management device 3. The information management device MGR may be arranged on the factory floor FL side, not on the monitoring room MR side.

The management device 3 includes a processing unit 31, a communication interface 32, an output unit 33, a first memory unit 34, a second memory unit 35, an input unit 36, an analysis unit 37, an event information memory unit 38, and a setting information memory unit 39.

The processing unit 31 controls the communication interface 32, the output unit 33, the first storage unit 34, the second storage unit 35, the input unit 36, the analysis unit 37, the event information storage unit 38, and the setting information storage unit 39. The processing unit 31 is configured using, for example, a CPU (Central Processing Unit) or an FPGA (Field Programmable Gate Array), and performs various processes and controls in cooperation with a memory (not shown). Specifically, the processing unit 31 refers to a program stored in the memory and executes the program to functionally realize the duplication processing unit 311 and the display processing unit 312. The processing unit 31 also acquires monitoring information from the communication interface 32 via the base station BS2, and event information and monitoring information from the information management device MGR. The processing unit 31 is an example of a monitoring information acquisition unit.

The communication interface 32 receives the monitoring information via the base station BS2. Here, the monitoring devices 2 (21-25) attached to the manufacturing equipment EQ arranged on the factory floor FL transmit the monitoring information to the management device 3 via a route separate from the communication line LI. In other words, the monitoring information transmitted by the monitoring devices 2 (21-25) reaches the management device 3 via the base stations BS1 and BS2.

The output unit 33 outputs the monitoring information acquired from the manufacturing equipment EQ and stored in the first storage unit 34 or the second storage unit 35 described below. The output unit 33 reads the monitoring information for a predetermined period including the occurrence time of the event selected by the input unit 36 from the storage unit (the first storage unit 34 and the second storage unit 35) and outputs it. The output unit 33 is typically a monitor (display) and displays the monitoring information. The output unit 33 may be a single monitor or a combination of multiple monitors. The output unit 33 may also be equipped with a speaker or the like that outputs sound. An example of the output of the monitoring information by the output unit 33 will be described later with reference to FIG. 5.

The first memory unit 34 stores monitoring information acquired from the manufacturing equipment EQ via the base station BS2 or the information management device MGR. Since the monitoring device constantly monitors the internal and external conditions of the manufacturing equipment EQ, the amount of monitoring information stored in the first memory unit 34 increases over time. On the other hand, since the storage capacity of the first memory unit 34 is a finite value, the first memory unit 34 accumulates monitoring information for a specified period, and monitoring information that has passed the specified period may be deleted.

The first storage unit 34 may store the monitoring information in an organized (sorted or grouped) form for each monitoring device. For example, a different file or folder may be created for each monitoring device in the first storage unit 34, and the monitoring information may be accumulated in that file or folder. In addition, when the first storage unit 34 is implemented using a database, an identifier capable of uniquely identifying the monitoring device (such as the ID, IP address, or MAC address of the monitoring device) may be set as a key for information search, and the monitoring information may then be registered in the database.

The second storage unit 35 stores a copy of the monitoring information required to identify the cause of an event (typically an error event) that has occurred in the manufacturing equipment EQ. The copy process of the monitoring information may be performed by the duplication processing unit 311 described below.

The input unit 36 may include a keyboard, mouse, touch panel, etc., and has a function as a human interface with the user, inputting user operations to the management device 3. The input unit 36 accepts the selection of the manufacturing equipment EQ (see FIG. 5). The input unit 36 accepts the selection of an event recorded in the event information (see FIG. 5). Furthermore, the input unit 36 accepts a setting input for setting the monitoring information to be output to the output unit 33 according to the content of the event. The setting value of the monitoring information to be output according to the content of the event (which monitoring information to output) may be stored in the setting information storage unit 39 in a format such as a table format (not shown).

The analysis unit 37 will be described later.

The event information storage unit 38 stores the event information received by the processing unit 31. This event information may be stored in the form of an event list (see the event list LST displayed in the display area SEC8 in Figure 5). The event list stored in the event information storage unit 38 may include information indicating the content of the event (event name) and information indicating the time (date and time) at which the event occurred. The event list is updated by the processing unit 31. The processing unit 31 updates the event list stored in the event information storage unit 38 based on the event information received from the information management device MGR.

The setting information storage unit 39 stores various setting values. The setting information storage unit 39 stores information indicating the correspondence between the manufacturing equipment EQ and the monitoring device.

Now, reference is made to FIG. 4. FIG. 4 is a conceptual diagram showing an example format of information indicating the correspondence between the manufacturing equipment EQ and the monitoring devices, stored in the setting information storage unit 39 of the management device 3 according to the embodiment. The information indicating the correspondence between the manufacturing equipment EQ and the monitoring devices may be stored in the setting information storage unit 39 in a tabular format such as the illustrated table T.

Table T has the following information items (table columns): "Manufacturing Equipment ID," "MDID," "IP Address," and "Sensor Type." The information item "Manufacturing Equipment ID" is ID information that can identify a manufacturing device. The information item "MDID" is ID information that uniquely identifies a monitoring device, and is an example of the identifier described above. The information item "IP Address" is an IP address (source IP address) assigned to a monitoring device, and is an example of the identifier described above. The information item "Sensor Type" is information that indicates the type of monitoring device. The manufacturing equipment cameras correspond to cameras CAM1 to CAM6 in FIG. 1. The floor cameras correspond to cameras CAM7 to CAM10 in FIG. 1.

Here, one monitoring device may correspond to multiple manufacturing equipment EQ. For example, a floor camera (CAM7 in FIG. 1) with an MDID of 20001 corresponds to manufacturing equipment EQ1 to EQ3. Therefore, table T contains multiple records (rows) with an MDID value of 20001.

By storing information indicating the correspondence between the manufacturing equipment EQ and the monitoring device in the setting information storage unit 39 in a format such as the above-mentioned table T, it is possible to identify the monitoring device that corresponds to the manufacturing equipment EQ selected by the user via the input unit 36. For example, the processing unit 31 can identify the monitoring device that corresponds to the selected manufacturing equipment EQ by extracting an "MDID" that uniquely identifies the monitoring device using the manufacturing equipment ID of the manufacturing equipment EQ selected by the user as a search key.

Conversely, the processing unit 31 can also identify the manufacturing equipment EQ that corresponds to the monitoring device by extracting the manufacturing equipment ID from table T using the "MDID" that uniquely identifies the monitoring device or the IP address information of the monitoring device as a search key.

Note that the format of the information indicating the correspondence between the manufacturing equipment EQ and the monitoring device is not limited to the above-mentioned table T.

The management device 3, which receives the monitoring information via base stations BS1 and BS2, references table T in the setting information storage unit 39 based on the MDID information or IP address (source IP address) information contained in the monitoring information. This reference makes it possible to identify which of the multiple manufacturing devices EQ1 to EQ6 the monitoring information relates to. The management device 3 stores the received monitoring information in the first storage unit 34, linked to the manufacturing device related to the monitoring information.

Refer to FIG. 3 again. The analysis unit 37 analyzes the monitoring information stored in the first storage unit 34 and the second storage unit 35, and identifies (or estimates) the cause of the occurrence of an event (error, etc.) in the manufacturing equipment EQ. This cause identification (estimation) can be realized by previously installing an analysis program in the analysis unit 37. The analysis program may be, for example, a program that uses information included in the event information (e.g., an event ID) and monitoring information acquired by the monitoring device at a time corresponding to the occurrence time of the event (e.g., a predetermined period including the occurrence time of the event) as input parameters, and outputs the identified or estimated cause of the error. As an example, information indicating the results of past error cause investigations (including cases where the operator WKR or the user of the management device 3 manually investigated) is stored in one of the storage areas in combination with the error content (event ID) and the event identified as the cause of the error (air leakage, an operation error by the operator WKR, a misalignment of the nozzle position setting, etc.). The analysis program may be a program that, when an event ID is input as an input parameter, displays on the output unit 33 events that are presumed to be the cause of an error, sorted in descending order of the number of times (or the probability) that they have been identified as the cause of an error in past error cause investigations.

When performing analysis using artificial intelligence, a trained model is implemented in the analysis unit 37. This trained model may be a trained model that, when information included in the event information is input, outputs the probability that an event that may cause an error (air leakage, an operation error by the worker WKR, a misalignment of the nozzle position setting, etc.) causes an error, or outputs a score value for the event. Such a trained model may be formed using information indicating the results of past investigations into the cause of errors (including investigations conducted manually by the worker WKR or a user of the management device 3, etc.). For example, the above-mentioned input parameters (whose causes have already been investigated) are input into a neural network constructed on the management device 3 or another cloud server, and machine learning is performed using information indicating events that have already been identified as the cause of errors as training data. In this way, the above-mentioned trained model is formed.

(Registration process of event information in the second storage unit 35)
When a previously anticipated event occurs in the manufacturing equipment EQ, the duplication processing unit 311 performs a process of duplication of a portion of the monitoring information related to the event from the first storage unit 34 to the second storage unit 35. This process is expressed as "registration of event information." For example, when the event the cause of which is to be identified is a "pickup error," the duplication processing unit 311 copies the monitoring information before and after the occurrence of the event from the first storage unit 34 to the second storage unit 35.

The monitoring information before and after the occurrence of the above-mentioned event that is copied from the first storage unit 34 to the second storage unit 35 is, for example, the monitoring information acquired by a monitoring device (which acquires monitoring information about the manufacturing equipment EQ in which the adsorption error occurred) during a period of M seconds before and after the time when the "adsorption error" occurred, and is copied from the first storage unit 34 to the second storage unit 35. M may be a different value for each event, and may be stored in the setting information storage unit 39 as setting information.

More specifically, the duplication processing unit 311 identifies the manufacturing equipment EQ in which the event occurred and the monitoring information of the monitoring device that corresponds to the manufacturing equipment EQ by referring to table T stored in the setting information storage unit 39. Alternatively, the duplication processing unit 311 extracts events from the event list stored in the event information storage unit 38 for which registration of event information in the second storage unit 35 has not yet been completed, and identifies the monitoring device and monitoring information related to the extracted event.

The duplication processing unit 311 copies only a predetermined time before and after the event occurrence time (e.g., M seconds before and after the event occurrence time) from the monitoring information of the identified monitoring device stored in the first storage unit 34 to the second storage unit 35 (registration of event information to the second storage unit 35). When copying, the duplication processing unit 311 stores the monitoring information to be registered in the second storage unit 35 in a state in which the manufacturing equipment ID, the event (such as the list number of the event list stored in the event information storage unit 38), and the event occurrence time are associated with the monitoring information to be registered in the second storage unit 35.

The timing of registering the event information in the second storage unit 35 does not have to be simultaneous with the occurrence of the event to be registered, so long as it is before the monitoring information is deleted from the first storage unit 34. For example, in nighttime batch processing, etc., the event information may be registered in the second storage unit 35 during a time period when the system load on the monitoring system is low.

Figure 5 is a diagram showing an example of output by the output unit 33 of the management device 3 according to the embodiment. Figure 5 shows an example in which an error occurs in the manufacturing device EQ2, the management device 3 receives event information indicating the error from the manufacturing device EQ2, and when investigating the cause of the error, information is output (displayed) on the output unit 33, which is a single monitor DISP.

In this example, the display area of the monitor DISP is divided into nine display areas SEC1 to SEC9. When displaying current monitoring information (monitoring mode) and when displaying (past) monitoring information for a specified period including the time when a selected event occurred (cause investigation mode), various information is displayed in the display areas SEC1 to SEC9. However, FIG. 5 is merely an example, and the display area does not have to be divided into nine areas, and the display format may be different from that shown in FIG. 5.

In addition, the speaker shown by the dashed line in the figure may be provided in the output unit 33 (monitor DISP), and the speaker may output the sound of the video being played, etc.

Display areas SEC1, SEC2, and SEC3 each display the manufacturing equipment EQ2 in which an error has occurred and is the display target. Display area SEC1 displays an image captured by camera CAM7, display area SEC2 displays an image captured by camera CAM2, and display area SEC3 displays an image captured by camera CAM8. Note that in the monitoring mode, these displayed images are current images. In the cause investigation mode, the displayed images are images captured (past) during a specified period including the time when the selected event occurred. The images may be stored in the first storage unit 34 or the second storage unit 35 as monitoring information.

Display area SEC4 displays the image of worker WKR operating manufacturing equipment EQ2. The image of worker WKR is captured by worker camera 22 of manufacturing equipment EQ2. In the monitoring mode, the captured image displayed is the current captured image. In the cause investigation mode, the captured image displayed is an image captured (past) for a predetermined period including the time when the selected event occurred. The captured image may be stored in first storage unit 34 or second storage unit 35 as monitoring information.

Display area SEC5 displays an image captured by the internal camera 21. For example, if the manufacturing equipment EQ2 is a chip mounter and the error is a "chip mounting error on the board," display area SEC5 displays an image of the location in manufacturing equipment EQ2 where the suction nozzle mounts the chip on the board. In the monitoring mode, the displayed image is the current image. In the cause investigation mode, the displayed image is an image captured during a specified period (past) that includes the time when the selected event occurred. The image may be stored in the first storage unit 34 or the second storage unit 35 as monitoring information.

When the captured image is a video, the playback mode may be controllable. A playback controller CTRL for controlling the playback of the video may be displayed in the display area SEC5 or the like. The playback controller CTRL may include, for example, from the left side of the display area SEC5 in the figure, a play/stop button for controlling playback or pausing of the video, a seek bar for controlling which time period in the video is displayed, a speed controller for controlling the playback speed of the video, a zoom-in button for zooming in on a part of the video that one wishes to focus on, and a zoom-out button for zooming out of the video. The configuration of the playback controller CTRL shown in the figure is merely an example, and the playback controller CTRL may have other configurations. In addition, the display contents of the other display areas SEC1 to SEC4 and SEC6 to SEC9 may change in synchronization with the playback control of the video by the playback controller CTRL. Furthermore, the playback controller CTRL may be displayed in an area other than the display area SEC5.

The display area SEC6 displays the manufacturing equipment ID of the manufacturing equipment selected as the display target and the name of the manufacturing equipment. Note that other information (e.g., a character string indicating whether the mode is monitoring mode or cause investigation mode) may also be displayed in the display area SEC6.

Display area SEC7 displays icons representing manufacturing equipment EQ1 to EQ6 arranged on floor FL. Of these, manufacturing equipment EQ2, which has been selected as the display target, is highlighted. The user can use input unit 36 to select another manufacturing equipment, for example, manufacturing equipment EQ4. The user can select the manufacturing equipment to be displayed by, for example, tapping the icon representing manufacturing equipment EQ4 (if the monitor DISP is a touch panel) or clicking the icon using a mouse or the like. When the user selects manufacturing equipment EQ4 via input unit 36, monitoring information corresponding to the selected manufacturing equipment EQ4 is displayed in the other display areas SEC1 to SEC6, SEC8, and SEC9.

In the display area SEC8, an event list LST and a button BTN are displayed. An enlarged view of the event list LST is shown in FIG. 6. The event list LST displays information about events that have occurred in a selected manufacturing device (in this example, manufacturing device EQ2) in list form. Display items displayed in the event list LST may be, for example, the time (date and time) when the event occurred and the event name. However, display items other than these may also be displayed in the event list LST.

The user can select any event from the event list LST displayed in the display area SEC8. This selection can be made by the user tapping (if the monitor DISP is a touch panel) or clicking on the line showing the event in the event list LST. When the user selects an event, (past) monitoring information about the selected event is displayed in the display areas SEC1 to SEC5 and SEC9 (cause investigation mode).

On the other hand, when the user presses button BTN (by tapping, clicking, etc.), current monitoring information for the selected manufacturing equipment EQ2 is displayed in display areas SEC1 to SEC5 and SEC9 (monitoring mode).

In the display area SEC9, statistical information about the selected manufacturing equipment EQ2 is displayed. For example, a histogram showing power consumption information of the manufacturing equipment EQ2, which is monitoring information acquired by the power meter 25, may be displayed as the statistical information. Also, a line graph showing temperature information inside the manufacturing equipment EQ2, which is monitoring information acquired by the thermometer 24, may be displayed. Although not shown, other monitoring information may be displayed in the display area SEC9. For example, the flow rate value of air flowing through the suction nozzle, which is acquired as monitoring information by the flow sensor 14, and the value of the load acting on the suction nozzle, which is acquired as monitoring information by the pressure sensor 15, may be displayed in the display area SEC9. The above statistical information may be displayed in a numerical format, or in a graph format such as a line graph or a histogram. In the monitoring mode, the displayed statistical information is current statistical information. In the cause investigation mode, the displayed statistical information is (past) statistical information for a predetermined period including the occurrence time of the selected event. These statistical information may be stored as monitoring information in the first storage unit 34 or the second storage unit 35.

The monitoring information as described above output to the output unit 33 may be synchronized with each other along the time axis. For example, as the playback of the video displayed in the display area SEC5 progresses along the time axis, the information displayed in the other display areas SEC1 to SEC4, SEC8, and SEC9 may follow and change along the time axis. In addition, audio information acquired by the microphone 23 may be output from a speaker provided in the output unit 33 in synchronization with the video displayed in the display area SEC5.

The output unit 33 may output information other than those exemplified above. For example, the output unit 33 may output two or more of monitoring information indicating the internal state of the manufacturing equipment EQ (flow sensor 14, pressure sensor 15, equipment internal camera 21, microphone 23, thermometer 24, power meter 25, etc.), monitoring information indicating the state of the worker operating the manufacturing equipment EQ (worker camera 22, etc.), and monitoring information indicating the external state of the manufacturing equipment EQ (CAM1 to CAM10, microphone 23, thermometer 24, etc.).

(Example of internal processing by the display processing unit 312)
In the monitoring mode, the output unit 33 (monitor DISP) outputs current monitoring information. When the user selects a manufacturing device (display area SEC7), the display processing unit 312 included in the processing unit 31 refers to a table T (FIG. 4) stored in the setting information storage unit 39, and outputs current information (LIVE information) obtained from each monitoring device corresponding to the selected manufacturing device to the output unit 33. This monitoring mode is used for normal monitoring operations. In the monitoring mode, an event list LST for the selected manufacturing device may be displayed in the display area SEC8. The display processing unit 312 may obtain event information for the selected manufacturing device from the event information storage unit 38, generate an event list LST, and display the event list LST in the display area SEC8.

In the cause investigation mode, the output unit 33 (monitor DISP) outputs (past) monitoring information for a predetermined period including the occurrence time of the selected event. When the user selects a manufacturing device (display area SEC7), the display processing unit 312 included in the processing unit 31 causes the output unit 33 to perform a display similar to that in the monitoring mode. When the user selects a past event from the event list LST (display area SEC8) that occurred in the manufacturing device, the display processing unit 312 retrieves monitoring information for a predetermined period including the occurrence time of the selected event from the second storage unit 35 and outputs it to the output unit 33 (monitor DISP).

When multiple types of monitoring information are output (displayed) to the output unit 33 (monitor DISP), the display processing unit 312 may synchronize the time of the information to be output (displayed). This time synchronization may cause the display areas SEC1 to SEC5 and SEC9 to display monitoring information at the same time.

If the monitoring information to be output (displayed) is not stored in the second storage unit 35, the display processing unit 312 may acquire the necessary information from the first storage unit 34. The display processing unit 312 may also acquire the monitoring information directly from each monitoring device that accumulates the information. The display processing unit 312 refers to table T or the like stored in the setting information storage unit 39 to identify the monitoring device corresponding to the selected manufacturing equipment, and outputs a predetermined time period (the present, or a predetermined period including the time when the selected event occurred) of the monitoring information acquired from the monitoring device to the output unit 33 (monitor DISP).

This allows the monitoring information acquired by the monitoring devices to be stored in the management device 3, and the monitoring information acquired by the monitoring devices to be output at the time corresponding to the time of occurrence of an event such as an abnormality, thereby making it possible to grasp the current state of the manufacturing equipment and the state before the abnormality occurred. As a result, a user of the management device 3 can investigate the cause of the abnormality and resolve it while being in a remote location (such as a monitoring room MR) that is different from the factory floor.

The system includes a setting information storage unit that stores the correspondence between the manufacturing equipment and the monitoring device, the input unit accepts the selection of the manufacturing equipment, and the output unit outputs the monitoring information that corresponds to the selected manufacturing equipment. This makes it possible to extract only the monitoring information related to a manufacturing equipment in which an error has occurred from among multiple manufacturing equipment arranged on a factory floor and output (display) it to the output unit. Even if a monitoring device is retrofitted to a manufacturing equipment, it is possible to identify the correspondence between the manufacturing equipment and the monitoring device from the information stored in the setting information storage unit, and extract only the monitoring information related to the manufacturing equipment in which an error has occurred and output (display) it to the output unit.

The monitoring device includes a worker camera that captures an image of a worker operating the manufacturing equipment. The event information acquisition unit acquires the event information indicating that the worker has operated the manufacturing equipment. This allows information (typically image information) indicating the facial expressions and behavior of the worker operating the manufacturing equipment to be accumulated in a management device, making it possible to identify an abnormality in the manufacturing equipment due to an operating error by the worker, etc.

The monitoring device includes one or more of a microphone, a thermometer, a hygrometer, a power meter, a flow sensor, a pressure sensor, and an object detection sensor. This makes it possible to monitor the state of the manufacturing equipment from various perspectives and identify the cause of an abnormality in the manufacturing equipment.

The output unit displays two or more of the monitoring information indicating the internal state of the manufacturing equipment, the monitoring information indicating the state of the worker operating the manufacturing equipment, and the monitoring information indicating the external state of the manufacturing equipment. This makes it possible to comprehensively monitor the internal and external states of the manufacturing equipment and the worker operating the manufacturing equipment, and to identify the cause of an abnormality in the manufacturing equipment from various perspectives.

The output unit outputs the monitoring information, which is an image, in a state in which it is possible to zoom in or out. The output unit also outputs the monitoring information, which is a video, in a state in which the playback speed is changed. Since manufacturing equipment such as chip mounters manufactures products by having small parts move at high speed, a user of a management device can properly grasp abnormalities in the manufacturing equipment with the naked eye by zooming in or playing back in slow motion, etc.

This disclosure is useful as a management device and management method that can grasp the current state of manufacturing equipment and the state before an abnormality occurs.

1 Manufacturing equipment main body 2 Monitoring device 3 Management device 11 Control unit 12 User interface 13 Working unit 14 Flow rate sensor 15 Pressure sensor 21 Equipment internal camera 22 Worker camera 23 Microphone 24 Thermometer 25 Power meter 31 Processing unit 32 Communication interface 33 Output unit 34 First memory unit 35 Second memory unit 36 Input unit 37 Analysis unit 38 Event information memory unit 39 Setting information memory unit 111 Log collection unit 311 Copy processing unit 312 Display processing unit BS1 Base station BS2 Base station BTN Buttons CAM1 to CAM10 Camera CTRL Playback controller DISP Monitor EQ, EQ1 to EQ6 Manufacturing equipment FL Factory floor LI Communication line LST Event list MGR Information management device MR Monitoring room PA Passage SEC1 to SEC9 Display area T Table WKR Worker

Claims (9)

A management device for managing a plurality of manufacturing devices arranged on a factory floor,
a monitoring information acquisition unit that acquires monitoring information from a plurality of monitoring devices, including one or more first monitoring devices that are arranged around the plurality of manufacturing equipment and monitor a status of the factory floor, and one or more second monitoring devices that are arranged inside each of the plurality of manufacturing equipment and monitor the status of the manufacturing equipment;
an event information acquisition unit that acquires event information including an occurrence time of an event that occurred in the plurality of manufacturing devices from the plurality of manufacturing devices;
a storage unit that stores the monitoring information and the event information;
an input unit that accepts a selection of an event recorded in the event information;
and an output unit that reads from the storage unit a plurality of pieces of monitoring information acquired from the first monitoring device and the second monitoring device for each of the plurality of manufacturing apparatuses during a predetermined period including an occurrence time of the selected event, and outputs a list of the plurality of pieces of monitoring information.
Management device. a setting information storage unit that stores a correspondence relationship between the manufacturing apparatus and each of the first monitoring device and the second monitoring device,
The input unit accepts a selection of the manufacturing device,
The output unit outputs the monitoring information corresponding to the selected manufacturing device.
The management device according to claim 1 . Each of the first monitoring device and the second monitoring device includes a worker camera that captures an image of a worker operating the manufacturing apparatus.
The management device according to claim 1 or 2. the event information acquisition unit acquires the event information indicating that the worker has operated the manufacturing device.
The management device according to claim 3 . Any one of the first monitoring device and the second monitoring device includes any one or more of a microphone, a thermometer, a hygrometer, a power meter, a flow sensor, a pressure sensor, and an object detection sensor.
The management device according to any one of claims 1 to 4. The output unit outputs the monitoring information, which is an image, in a state in which the image can be zoomed in or out.
The management device according to any one of claims 1 to 5. The output unit outputs the monitoring information, which is a video, with a playback speed changed.
The management device according to any one of claims 1 to 6. The output unit,
In the case of a cause investigation mode of an event of the manufacturing device,
outputting a list of a plurality of pieces of monitoring information for the predetermined period including the occurrence time of the selected event;
In the case of a monitoring mode of the manufacturing device,
outputting a list of monitoring information currently acquired by each of the first monitoring device and the second monitoring device;
The management device according to any one of claims 1 to 7. A method for managing a plurality of manufacturing devices arranged on a factory floor by a management device, comprising:
acquiring monitoring information from a plurality of monitoring devices, including one or more first monitoring devices arranged around the plurality of manufacturing equipment to monitor a status of the factory floor and one or more second monitoring devices arranged inside each of the plurality of manufacturing equipment to monitor a status of the manufacturing equipment;
acquiring event information from the plurality of manufacturing devices, the event information including an occurrence time of an event that occurred in the plurality of manufacturing devices;
storing the monitoring information and the event information;
accepting a selection of an event recorded in the event information;
and outputting a list of the plurality of pieces of monitoring information acquired from the first monitoring device and the second monitoring device for each of the plurality of manufacturing apparatuses during a predetermined period including an occurrence time of the selected event.
How to manage it.

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