JP7710189B2 - Production planning method, production planning system, and production planning program - Google Patents

Description

The present invention relates to a production planning method, a production planning system, and a production planning program for creating a production plan for producing multiple types of mounted boards using a component mounting line.

When producing products such as mounted circuit boards with components mounted on a board using multiple production lines equipped with production equipment, a production plan is created that includes the allocation of product types to each production line and the production sequence so that multiple product types can be produced in specified quantities by specified production delivery dates. In addition, production data is created for each production line, including the configuration of the production equipment to match the product types to be produced. When creating the production data, the configuration of the production equipment is created so that there are fewer changeovers to change the configuration of the production equipment when changing the product type.

Meanwhile, on a production line, production data cannot be created until a production plan has been created and the type of product to be produced has been decided; conversely, if the production data has not been decided, the exact time required to produce the type cannot be calculated, and a highly accurate production plan cannot be created. In other words, the production plan and production data are in a circular reference relationship, and in order to simultaneously create a production plan and production data with high prediction accuracy and production efficiency, a highly skilled, experienced creator must spend a long time creating them. Patent Document 1 describes a system that supports workers in creating a production plan and production data (processing process plan) simultaneously.

International Publication No. 2013/137159

When creating a production plan, production plans and production data may be created for multiple product varieties to be produced next for multiple production lines that are currently producing products. However, conventional technologies, including the system described in Patent Document 1, do not take into account the current production situation, and the quality of the created production plans and production data depends on the skills of the workers. In addition, there are problems with the time required for the creation work increasing exponentially as the number of product varieties to be produced increases.

The present invention aims to provide a production planning method, production planning system, and production planning program that can create the next production plan based on the current status of the component mounting line.

The production plan creation method of the present invention is a production plan creation method for creating a production plan for producing mounted boards of multiple production varieties by a component mounting line equipped with a component mounting device that mounts components supplied by a component supply device onto a board, the production plan assigning multiple production varieties to the multiple component mounting lines, and includes a step of acquiring the current configuration of the component mounting device equipped to the multiple component mounting lines, a step of acquiring information on the production variety to be produced in the future, a step of calculating a similarity rate between the production variety to be produced in the future and a production variety that can be produced with the current configuration of the component mounting device, and a step of creating a production plan in which the production variety to be produced in the future is assigned to one of the multiple component mounting lines based on the similarity rate.

The production planning system of the present invention is a production planning system that creates a production plan for producing multiple production types of mounted boards by multiple component mounting lines equipped with component mounting devices that mount components supplied by component supply devices onto boards, and includes a similarity calculation unit that calculates a similarity between the production type to be produced and a production type that can be produced with the current configuration of the component mounting devices based on the current configuration of the component mounting devices equipped in the component mounting lines and information on the production type to be produced, and a production planning unit that creates a production plan in which the production type to be produced is assigned to one of the multiple component mounting lines based on the similarity.

The production plan creation program of the present invention is a production plan creation program that causes a computer to execute the creation of a production plan for producing a plurality of production types of mounted boards by a plurality of component mounting lines equipped with component mounting devices that mount components supplied by a component supply device onto a board, and includes the steps of: acquiring the current configuration of the component mounting devices equipped in the component mounting lines; acquiring information on the production type to be produced in the future; calculating a similarity rate between the production type to be produced in the future and a production type that can be produced in the current configuration of the component mounting devices; and creating a production plan that assigns the production type to be produced in the future to one of the plurality of component mounting lines based on the similarity rate.

According to the present invention, the next production plan can be created based on the current status of the component mounting line.

FIG. 1 is a configuration explanatory diagram of a component mounting system according to an embodiment of the present invention; FIG. 1 is a configuration explanatory diagram of a component mounting line provided in a component mounting system according to an embodiment of the present invention; FIG. 2 is a plan view of a component mounting device provided in a component mounting line according to an embodiment of the present invention. FIG. 1 is a partial cross-sectional view of a component mounting device provided in a component mounting line according to an embodiment of the present invention. FIG. 1 is a block diagram showing the configuration of a management computer (production planning system) according to an embodiment of the present invention. FIG. 2 is an explanatory diagram of an example of production plan information used in a management computer (production plan creation system) according to an embodiment of the present invention; FIG. 2 is an explanatory diagram of a production plan for next week created in a management computer (production planning system) according to an embodiment of the present invention. FIG. 13 is an explanatory diagram of an example of a changeable range setting screen displayed on a display unit of a management computer (production planning system) according to an embodiment of the present invention; FIG. 1 is an explanatory diagram of an example of a similarity rate calculated in a management computer (production planning system) according to an embodiment of the present invention. FIG. 1A is an explanatory diagram of an example of a leading plan created in a management computer (production plan creation system) according to an embodiment of the present invention; FIG. 1B is an explanatory diagram of an example of a production plan; FIG. 1 is a flow diagram of a production plan creation method according to an embodiment of the present invention. FIG. 1 is a flow diagram of a method for creating a front-end plan according to an embodiment of the present invention;

An embodiment of the present invention will be described in detail below with reference to the drawings. The configurations, shapes, etc. described below are illustrative examples and can be modified as appropriate depending on the specifications of the component mounting system, component mounting line, management computer, component mounting device, etc. In the following, the same reference numerals are used for corresponding elements in all drawings, and duplicated explanations will be omitted. In FIG. 3 and some of the drawings described below, the X direction (left-right direction in FIG. 3) of the board transport direction and the Y direction (up-down direction in FIG. 3) perpendicular to the board transport direction are shown as two axial directions perpendicular to each other in the horizontal plane. In FIG. 4, the Z direction (up-down direction in FIG. 4) is shown as the height direction perpendicular to the horizontal plane. The Z direction is the up-down direction or perpendicular direction when the component mounting device is installed on a horizontal plane.

First, the configuration of component mounting system 1 will be described with reference to FIG. 1. Component mounting system 1 is configured to connect three component mounting lines L1-L3 arranged on floor F via a communication network 2 and manage them using a management computer 3. Component mounting lines L1-L3 are arranged in a production area Ap provided on floor F. As described below, each component mounting line L1-L3 is configured by connecting multiple production facilities including a screen printing device and a component mounting device, and has the function of producing mounted boards (products) with components mounted on a board. Note that component mounting system 1 does not need to have three component mounting lines L1-L3, and may have one, two, four or more.

In a preparation area As, which is different from the production area Ap provided on floor F, a placement work support device 4 is placed. The placement work support device 4 is connected to a management computer 3 via a communication network 2. A replacement cart 5, which is the subject of placement work described below, is connected to the placement work support device 4. A plurality of carts 5 in various states, such as before, during, or after placement work, are stored in the preparation area As. In addition, the preparation area As stores removable elements such as a plurality of screen masks, tape feeders 9, mounting heads 12, suction nozzles 12b, and reels 17 (see FIG. 4), which are shared by the production equipment arranged on floor F.

In FIG. 1, a placement operation is performed on a trolley 5 connected to a placement support device 4 according to work instructions corresponding to the type of mounted board to be produced on component mounting lines L1 to L3. The placement operation is performed by a worker who removes from the trolley 5 a number of tape feeders 9 and reels 17 that supply the specified components, and installs them in the specified positions on the trolley 5. For trolleys 5 in the preparation area As, including trolleys 5 connected to the placement support device 4, placement operation can be performed in parallel with the production of mounted boards on component mounting lines L1 to L3. Hereinafter, the preparation operation for a type change outside of component mounting lines L1 to L3, including the placement operation on the trolley 5, is referred to as off-site setup operation.

When changing the type of mounted board produced in component mounting lines L1-L3, workers move the cart 5 that has completed placement work in the preparation area As to component mounting lines L1-L3 and perform cart replacement work to replace it with the cart 5 attached to the component mounting device. In addition, in the product type switching work, workers move the replacement screen mask, tape feeder 9, mounting head 12, suction nozzle 12b, reel 17, etc. stored in the preparation area As to component mounting lines L1-L3 and replace them. Hereinafter, the preparation work for product type changes within component mounting lines L1-L3 will be referred to as internal setup work.

Next, the detailed configuration of component mounting lines L1 to L3 will be described with reference to Figure 2. Component mounting lines L1 to L3 have the same configuration, and below, component mounting line L1 will be described. Component mounting line L1 is configured by connecting production equipment such as board supply device M1, screen printing device M2, component mounting devices M3 to M6, reflow device M7, and board removal device M8 in series from the upstream side (left side of the paper) to the downstream side (right side of the paper) in the board transport direction. Note that component 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.

The board supply device M1, the screen printing device M2, the component mounting devices M3 to M6, the reflow device M7, and the board removal device M8 are connected to the management computer 3 via the communication network 2. The board supply device M1 has a storage section such as a rack that stores multiple boards, and performs a board supply operation in which the boards removed from the storage section are supplied to downstream devices. The screen printing device M2 performs a solder printing operation in which solder is printed on the boards brought in from the upstream side through a screen mask attached to the printing operation section. The component mounting line L1 may also be provided with a solder application device that applies solder to the boards using a dispenser, either in parallel with the screen printing device M2 or instead of the screen printing device M2. The screen printing device M2 and the solder application device are printing devices that deposit solder on the boards.

The component mounting devices M3 to M6 perform component mounting work by mounting components on a board on which solder has been deposited using a mounting head 12. Note that the component mounting line L1 is not limited to a configuration of four component mounting devices M3 to M6, and may have one to three or five or more component mounting devices M3 to M6. The reflow device M7 performs a board heating work in which the board carried into the device is heated by a board heating unit to harden the solder on the board and bond the electrode part of the board to the component. The board recovery device M8 has a storage unit such as a rack that stores multiple boards, and performs a board recovery work in which it receives boards carried out by an upstream device and recovers them in the storage unit.

Next, the configuration of component mounting devices M3 to M6 will be described with reference to Figures 3 and 4. Component mounting devices M3 to M6 have the same configuration, and component mounting device M3 will be described here. Component mounting device M3 has the function of mounting components D on board B. In Figure 3, a board transport mechanism 7 is installed in the X direction at the center of base 6. Board transport mechanism 7 transports board B carried in from the upstream side in the X direction, and positions and holds it at a mounting work position by mounting head 12, which will be described below. In addition, board transport mechanism 7 transports board B downstream after component mounting work has been completed. Component supply units 8 are installed on both sides of board transport mechanism 7.

Attached to the component supply unit 8 are carts 5 on which multiple tape feeders 9 are mounted in parallel in the X direction. The tape feeders 9 feed the carrier tape, on which pockets for storing the components D are formed, in a pitch direction from the outside of the component supply unit 8 toward the board transport mechanism 7 (tape feed direction) to supply the components D to the component removal position where the mounting head 12 picks up the components D. In other words, the tape feeder 9 is a component supply device that supplies the components D. Note that the component supply device may be a tray feeder that supplies the components D placed on a tray, a stick feeder that supplies the components D aligned and held in a hollow stick, or the like, in addition to the tape feeder 9.

In FIG. 3, a Y-axis table 10 equipped with a linear drive mechanism is disposed on both ends in the X direction on the top surface of the base 6. A beam 11 similarly equipped with a linear mechanism is connected to the Y-axis table 10 so as to be freely movable in the Y direction. A mounting head 12 is attached to the beam 11 so as to be freely movable in the X direction. The mounting head 12 is equipped with multiple (eight in this case) nozzle units 12a. Multiple types of mounting heads 12, differing in the number of nozzle units 12a, are available.

In FIG. 4, a suction nozzle 12b that vacuum-sucks and holds a component D is attached to the lower end of each nozzle unit 12a. There are multiple types of suction nozzles 12b with different nozzle shapes corresponding to the size and shape of the component D to be sucked.

In FIG. 3, the Y-axis table 10 and the beam 11 constitute a mounting head moving mechanism 13 that moves the mounting head 12 in the horizontal direction (X direction, Y direction). The mounting head moving mechanism 13 and the mounting head 12 pick up the component D by suction with the suction nozzle 12b from the component removal position of the tape feeder 9 attached to the component supply unit 8. The mounting head moving mechanism 13 then transports the mounting head 12 to the mounting position of the board B held by the board transport mechanism 7 and performs the component mounting work.

The time it takes for the mounting head 12 to pick up components D from the tape feeder 9 and mount them on the board B depends on the position of the tape feeder 9 on the carriage 5 (the configuration of the component mounting device). For example, by positioning the tape feeder 9, which supplies components D that are mounted in large numbers on the board B, near the center of the carriage 5, the travel distance of the mounting head 12 can be reduced, thereby shortening the mounting time.

In Figures 3 and 4, the beam 11 is fitted with a head camera 14 that is positioned on the underside of the beam 11 and moves integrally with the mounting head 12. As the mounting head 12 moves, the head camera 14 moves above the board B that is positioned at the mounting operation position of the board transport mechanism 7, and captures an image of a board mark (not shown) provided on the board B to recognize the position of the board B.

A component recognition camera 15 is installed between the component supply unit 8 and the board transport mechanism 7. When the mounting head 12 moves upward after picking up a component D from the component supply unit 8, the component recognition camera 15 captures an image of the component D held by the suction nozzle 12b to recognize the holding position, etc. When the mounting head 12 mounts the component D on the board B, the mounting position is corrected taking into account the recognition results of the board B by the head camera 14 and the recognition results of the component D by the component recognition camera 15.

In FIG. 4, a reel 17 on which a carrier tape 16 storing a component D is wound is held at the front of the cart 5. The tape feeder 9 transports the carrier tape 16 stored on the reel 17 in the tape feed direction to supply the component D to a component pick-up position by the mounting head 12. There are multiple types of tape feeders 9 with different widths corresponding to the width of the carrier tape 16 to be transported.

As such, the component mounting lines L1-L3 are equipped with component mounting devices M3-M6 that mount components D supplied by tape feeders 9 (component supply devices) onto the board B. Each of the component mounting devices M3-M6 is equipped with two carts 5 on which multiple tape feeders 9 (component supply devices) that supply different types of components D are arranged. In other words, each of the component mounting lines L1-L3, which are equipped with four component mounting devices M3-M6, is equipped with eight carts 5. Hereinafter, the multiple carts 5 installed on the component mounting lines L1-L3 to produce mounted boards will be referred to as a "cart group."

Next, the configuration of the management computer 3 will be described with reference to FIG. 5. The management computer 3 includes a processing unit 20, a production plan storage unit 21, a production data storage unit 22, a line information storage unit 23, and a performance information storage unit 24, which are storage devices, as well as an input unit 25 and a display unit 26. The processing unit 20 is a data processing device such as a CPU, and includes an performance information collection unit 27, an information acquisition unit 28, a range setting unit 29, a similarity rate calculation unit 30, a leading plan creation unit 31, an equipment configuration creation unit 32, a switching time calculation unit 33, a condition determination unit 34, a cycle time calculation unit 35, a group creation unit 36, a production plan update unit 37, a predicted time calculation unit 38, and a delay determination unit 39 as internal processing units.

The input unit 25 is an input device such as a keyboard, touch panel, or mouse, and is used for inputting operation commands and data. The display unit 26 is a display device such as an LCD panel, and in addition to displaying various data stored in each memory unit, displays various information such as an operation screen for operation by the input unit 25 and a changeable range setting screen. Note that the management computer 3 does not need to be configured as a single computer, and may be configured as multiple devices. For example, all or part of the storage device may be provided in the cloud via a server.

In FIG. 5, the production plan storage unit 21 stores production plan information 21a, product type information 21b, cycle time information 21c, switching time information 21d, etc. The production plan information 21a stores a production plan for each lot number that identifies the lot of the mounted board to be produced, including information identifying the type of the mounted board, the number of pieces to be produced, the date and time when production can be started and the production delivery date, information identifying the component mounting lines L1 to L3 that produce the mounted boards, the scheduled start date and time and the scheduled end date and time, and the worker work schedule.

Now, referring to FIG. 6, an example of the production plan information 21a will be described. The production plan information 21a includes a lot number 41, a product type number 42, a production quantity 43, a start date and time 44, and a production delivery date 45. The lot number 41 is information that identifies the lot of mounted boards produced on the component mounting lines L1 to L3. The product type number 42 is information that identifies the product type of the mounted board. The production quantity 43 is the number of mounted boards produced in the lot. The start date and time 44 is the date and time when the components D and the like are available on floor F and production can start. The production delivery date 45 is the date and time when the production of the mounted boards must be completed. Hereinafter, a lot with a lot number 41 of "A" will be simply referred to as "lot A", and a product type with a product type number 42 of "X1" will be simply referred to as "product type X1", etc.

In FIG. 5, product type information 21b stores, for each product type number 42, information necessary for component mounting work, such as the component type and mounting position of component D to be mounted on board B. Cycle time information 21c stores, for each lot number 41 (or product type number 42), the maximum cycle time from when board B is carried into the production equipment equipped in component mounting lines L1 to L3 until the production work is performed and it is carried out, for each lot number 41 (or product type number 42). Switching time information 21d stores the external setup work time, cart change time, and internal setup work time for switching the product type to be produced, in association with the product type combination before and after the switch.

In FIG. 5, the production data storage unit 22 stores production data information 22a and the like. The production data information 22a stores information about the configuration of the production equipment, such as the positions of the tape feeders 9 and reels 17 on the carriage 5, and the positions and types of the mounting heads 12 and suction nozzles 12b attached to the component mounting devices M3 to M6, for each type (or lot) assigned to the component mounting lines L1 to L3. In addition, when the types (or lots) assigned to the component mounting lines L1 to L3 are grouped, the production data information 22a also includes information about the types (or lots) that belong to the same group, and the positions of the tape feeders 9 and reels 17 that are commonly arranged on multiple carriages 5 (cart groups).

The line information storage unit 23 stores line configuration information 23a, standard operation time information 23b, and the like. The line configuration information 23a stores information about the configuration of the component mounting lines L1 to L3, such as the type of production equipment that makes up the component mounting lines L1 to L3 and the order in which they are connected. The standard operation time information 23b stores information about the standard operation time required for production, such as the standard required time for production work, for each piece of production equipment that makes up the component mounting lines L1 to L3. For example, the standard operation time information 23b stores the time to carry in and out the board B at each piece of production equipment, the printing time per board at the screen printing device M2, and the mounting time per component at the component mounting devices M3 to M6.

In FIG. 5, the performance information storage unit 24 stores production performance information 24a, equipment configuration information 24b, and the like. The production performance information 24a stores the production start date and time, production end date and time, and the number of boards produced for each lot number 41 of mounted boards that have been produced or are being produced on the component mounting lines L1 to L3. The equipment configuration information 24b stores the configuration of the production equipment of the component mounting lines L1 to L3 when the mounted boards are produced for each lot number 41 (or product number 42).

In this embodiment, the management computer 3 creates a "production plan for next week" as a production plan. Next week's production plan created by the management computer 3 will now be described with reference to FIG. 7. At the "current time" in the figure, mounted boards with lot number 41 included in the planned production variety 46a in the production plan information 21a shown in FIG. 6 are being produced. That is, lot P is being produced on component mounting line L1, lot Q is being produced on component mounting line L2, and lot R is being produced on component mounting line L3. Next week's production plan is a production plan for mounted boards to be produced after the "shift start time next week" in the figure.

In other words, next week's production plan is a production plan for producing mounting boards from lot A onwards, which are included in the planned production variety 46b of the production plan information 21a shown in FIG. 6. Note that the production plan created by the management computer 3 is not limited to next week's production plan, and the management computer 3 creates the next production plan following the already created production plan. For example, if a production plan has already been created up to today, a production plan from tomorrow onwards is created following the production plan up to today. Hereinafter, the next production plan created by the management computer 3 following the already created production plan, including next week's production plan, will be referred to simply as the "next production plan".

In FIG. 5, the performance information collection unit 27 sequentially collects information such as production performance from each piece of production equipment on the component mounting lines L1 to L3, and stores it in the performance information storage unit 24 as production performance information 24a and equipment configuration information 24b. In other words, the equipment configuration information 24b stores at least the current configuration of the component mounting devices M3 to M6 equipped on the multiple component mounting lines L1 to L3.

The information acquisition unit 28 acquires information necessary to create the next production plan. Specifically, the information acquisition unit 28 collects information on the lot number 41, product number 42, production quantity 43, possible start date and time 44, and production delivery date 45 of the production product type to be produced next (planned production product type 46b) from the production plan information 21a, and collects the component type of component D to be mounted on board B of the planned production product type 46b from the product type information 21b. The information acquisition unit 28 also collects information on the production product type currently being produced on component mounting lines L1 to L3 from the production performance information 24a, and information on the current configuration of component mounting devices M3 to M6 from the equipment configuration information 24b.

When the next production plan is created, if production of the last lot in the previously created production plan has not yet begun, the information acquisition unit 28 acquires information on the configuration of component mounting devices M3 to M6 planned for production of the last lot from the production data information 22a, instead of information on the current configuration of component mounting devices M3 to M6. In other words, the "current configuration of component mounting devices M3 to M6" acquired by the information acquisition unit 28 is the "configuration of component mounting devices M3 to M6 when producing the last lot planned in the previously created production plan."

In FIG. 5, the range setting unit 29 sets the changeable range when switching the configuration of component mounting devices M3 to M6 from a configuration (current configuration) for producing the last lot of a production plan that has already been created to a configuration for producing the first lot of the next production plan. Specifically, the range setting unit 29 displays a changeable range setting screen on the display unit 26, and sets the changeable range based on information input by the administrator by operating the input unit 25.

Now, referring to FIG. 8, an example of the changeable range setting screen 47 displayed by the range setting unit 29 on the display unit 26 will be described. The changeable range setting screen 47 displays a "condition setting" area 48, a "producible product type setting" area 49, a "cancel" button 50, and a "set" button 51. The "condition setting" area 48 displays input fields 48a for inputting the "similarity rate," "number of replacement feeders," "number of workers," and "work time."

The similarity rate is the ratio of similarity between the planned production variety 46b and the mounting boards that can be produced with the current configuration of component mounting devices M3 to M6. Specifically, the similarity rate calculation unit 30 calculates the similarity rate as the ratio of the component types that can be mounted on board B with the current configuration of component mounting devices M3 to M6 and the component types required for the production of the planned production variety 46b. In the example of FIG. 8, the similarity rate is set to "90% or more." This means that when producing the planned production variety 46b, the range of component types that can be changed from the current configuration of component mounting devices M3 to M6 is "less than 10%" of the total.

Now, referring to FIG. 9, an example of the similarity rate 52 calculated by the similarity rate calculation unit 30 will be described. FIG. 9 shows the similarity rate 52 calculated for the current configuration in which lot P (product type Y7) is produced on component mounting line L1 (line L1), lot Q (product type Y8) is produced on component mounting line L2 (line L2), and lot R (product type Y9) is produced on component mounting line L3 (line L3) shown in FIG. 7, with product types X1 to X8 in FIG. 6 being the planned production product types 46b. That is, for each product type number 42, a similarity rate 52a for production on line L1, a similarity rate 52b for production on line L2, and a similarity rate 52c for production on line L3 are displayed.

In FIG. 8, the number of replacement feeders is the upper limit of the number of tape feeders 9 (component supply devices) that are permitted to be replaced from the current component mounting devices M3 to M6. The number of workers is the upper limit of the number of workers that can be assigned to perform the work for changing the product type. The working time is the upper limit of the working time permitted for the work for changing the product type.

In the "Producible product setting" area 49, the products that will remain as producible products (producible products) from among the planned production products 46a are set. The management computer 3 creates a production plan for the planned production products 46b within the range in which the producible products can be produced. The manager uses the input unit 25 to slide the scroll bar 49a and operate the selection button 49b (setting it to a black square in the figure) to set the producible product.

In FIG. 8, when the "Cancel" button 50 is operated, the screen transitions from the changeable range setting screen 47 to the previous screen. When the "Set" button 51 is operated, the range setting unit 29 sets the range that can be changed from the current configuration based on the conditions set in the "Condition setting" area 48 and the "Producible product type setting" area 49. For example, the range setting unit 29 sets the strictest condition among the conditions in the "Condition setting" area 48 and the "Producible product type setting" area 49 as the changeable range. Note that the range setting unit 29 may set any one of the conditions as the changeable range.

In this way, the range setting unit 29 sets the changeable range based on at least one of the number of component supply devices (tape feeders 9) (number of replacement feeders) arranged on component mounting devices M3 to M6, the number of workers (number of workers) who change the configuration of component mounting devices M3 to M6, the time (work time) required to change the configuration of component mounting devices M3 to M6, and the product types (producible product types) that can be produced on component mounting lines L1 to L3.

In FIG. 5, the leading plan creation unit 31 creates a leading plan in which the planned production type 46b (hereinafter referred to as the "leading production type") to be produced first on the component mounting lines L1 to L3 in the next production plan is assigned to each of the component mounting lines L1 to L3 based on the similarity rate 52. Specifically, the planned production type 46b is assigned to the multiple component mounting lines L1 to L3 in descending order of similarity rate 52.

In the example of FIG. 9, first, the leading plan creation unit 31 assigns lot E of type X5, which has the highest similarity rate 52 of 94%, to component mounting line L1. Next, the leading plan creation unit 31 assigns lot B of type X2, which has the next highest similarity rate 52 of 92%, to component mounting line L2. The next highest similarity rate 52 is lot E of type X5, which has a similarity rate 52 of 92%, but lot E has already been assigned to component mounting line L1. Therefore, the leading plan creation unit 31 assigns lot F of type X6, which has the next highest similarity rate 52 of 91%, to component mounting line L3.

In FIG. 5, if the changeable range conditions set by the range setting unit 29 are met, the leading plan creation unit 31 creates a leading plan that assigns the leading production variety to the component mounting lines L1 to L3, and stores the plan in the production plan information 21a. If the changeable conditions are not met, the leading plan creation unit 31 displays a warning on the display unit 26 that the allocation is not possible, and prompts the manager to take measures such as relaxing the changeable range. In the example of FIG. 9, if the changeable range is "similarity rate 90% or more," the leading production variety can be assigned to all component mounting lines L1 to L3. If the changeable range is "similarity rate 92% or more," there is no leading production variety that can be assigned to component mounting line L3, so the leading plan creation unit 31 displays a warning to that effect on the display unit 26.

In this way, the leading plan creation unit 31 is a production plan creation unit that creates a production plan in which the planning target production variety 46b (the production variety to be produced in the future) is allocated to multiple component mounting lines L1 to L3 based on the similarity rate 52 under the condition that the configuration of component mounting devices M3 to M6 is changed from the current configuration within a predetermined changeable range when producing the planning target production variety 46b (the production variety to be produced in the future). Note that if adding the cart replacement work of the spare cart group is within the predetermined changeable range, the leading plan creation unit 31 may create a leading plan that includes the cart replacement work. In this case, the similarity rate calculation unit 30 calculates the similarity rate 52 for the virtual component mounting devices M3 to M6 equipped with the spare cart group.

In FIG. 5, the equipment configuration creation unit 32 determines the configuration of each production facility including component mounting devices M3-M6 for each lot based on the assigned component mounting lines L1-L3, groups, information on production sequence, product type information 21b, and equipment configuration information 24b contained in the production plan information 21a, and stores the determined configuration in the production data information 22a. When lots are grouped, the equipment configuration creation unit 32 determines the configuration of the production facilities so that the tape feeders 9 and reels 17 are commonly arranged on the trolleys 5 so that lots belonging to the group can be produced without the need to replace the trolleys 5.

The switching time calculation unit 33 calculates (predicts) the switching time for changing the configuration of the component mounting devices M3-M6 in each component mounting line L1-L3 to the next production type based on the number of workers set by the range setting unit 29 and the production data information 22a. When switching to a type within the group, the switching time includes the internal setup work time for replacing the tape feeders 9 and reels 17 of the carts 5 attached to the component mounting devices M3-M6. When switching to a type outside the group, the switching time further includes the cart replacement work time for replacing the carts 5 (cart group) prepared in the external setup work with the carts 5 attached to the component mounting devices M3-M6.

The switching time calculation unit 33 stores the calculated switching time as switching time information 21d in the production plan storage unit 21. In the production plan (leading plan) shown in FIG. 10(a), the internal setup work time predicted to be required to configure component mounting devices M3 to M6 to produce lots E, B, and F is displayed by diagonal hatching.

In FIG. 5, the condition determination unit 34 determines whether the configuration of component mounting devices M3 to M6 determined by the equipment configuration creation unit 32 and the internal setup work time calculated by the switching time calculation unit 33 satisfy the changeable range set by the range setting unit 29. If the calculated internal setup work time exceeds the set work time, the condition determination unit 34 determines that the set changeable range is not satisfied. In addition, if the number of component supply devices (tape feeders 9) to be replaced to achieve the determined configuration of component mounting devices M3 to M6 exceeds the set number of replacement feeders, the condition determination unit 34 determines that the set changeable range is not satisfied.

The cycle time calculation unit 35 calculates the cycle time per mounting board required to produce the planned production type 46b based on the production equipment configuration and standard operation time information 23b included in the production data information 22a, and stores this in the cycle time information 21c. The cycle time calculation unit 35 also multiplies the calculated cycle time by the number of mounting boards to be produced 43 to calculate the production time required to produce the planned production type 46b. In the production plan (leading plan) shown in Figure 10(a), the production times of lots E, B, and F on component mounting lines L1 to L3 are displayed as rectangles. The length of the rectangle along the production time is the production time.

In FIG. 5, the group creation unit 36 calculates the commonality of parts between multiple planned production varieties 46b based on variety information 21b of the planned production varieties 46b (production varieties to be produced in the future), and groups the tape feeders 9 and reels 17 for the multiple varieties into groups in which they are commonly placed on a cart 5 (cart group) based on the calculated commonality. In FIG. 10(b), of the planned production varieties 46b, varieties X5 (lot E), X3 (lot C), and X4 (lot D) have a high commonality and are grouped into a group. Similarly, varieties X7 (lot G) and X8 (lot H) also have a high commonality and are grouped into a group.

In FIG. 5, the production plan update unit 37 assigns planned production varieties 46b other than the leading production variety to component mounting lines L1 to L3 for the leading plan to which the leading production variety is assigned based on the production plan information 21a. The production plan update unit 37 updates (creates) the production plan so that planned production varieties 46b of the same group are produced consecutively. Alternatively, the production plan update unit 37 changes the production sequence of the assigned planned production varieties 46b. The created production plan is stored in the production plan storage unit 21 as production plan information 21a.

The predicted time calculation unit 38 calculates the predicted production completion time of the target production variety based on the production plan created by the production plan update unit 37, the switching time calculated by the switching time calculation unit 33 (cart exchange work time, internal setup work time), and the production time calculated by the cycle time calculation unit 35. That is, the predicted time calculation unit 38 calculates the predicted production completion time of the target production variety, including the switching time, based on the production volume (production number 43) of the planned production variety 46b (production variety to be produced) and the created production plan.

In FIG. 5, the delay determination unit 39 determines whether there is a product type (lot) whose predicted production end time will be later than the production delivery date 45 based on the production completion forecast time calculated by the forecast time calculation unit 38 and the production delivery date 45 included in the production plan information 21a. In other words, the delay determination unit 39 determines whether the production completion forecast time will delay the production delivery date 45 of the planned production product type 46b.

When the delay determination unit 39 determines that there will be a delay, the production plan update unit 37 changes the allocation of the planned production type 46b in the production plan to the component mounting lines L1 to L3, or the production sequence of the planned production type 46b. By repeating delay determination and production plan changes, a production plan (production plan information 21a) and production data (production data information 22a) that meet the production delivery date 45 are simultaneously created.

Now, referring to FIG. 10(b), an example of a production plan created by the production plan update unit 37 will be described. In the component mounting line L1, the production of lot C (product type X3) and lot D (product type X4), which are in the same group as lot E, is assigned after product type X5 (lot E). Switching from lot E to lot C and from lot C to lot D is only an internal setup operation that does not involve exchanging the trolley 5. In the component mounting line L2, the production of lot A (product type X1), which is not in the same group as lot B, is assigned after product type X2 (lot B), which is the first production product. Switching from lot B to lot A is performed by a trolley exchange operation in which the trolley 5 (a group of trolleys) prepared in advance in the external setup operation is exchanged for the trolley 5 attached to the component mounting device M3 to M6.

On component mounting line L3, following the leading production variety, variety X6 (lot F), lots G (variety X7) and H (variety X8) are assigned, which belong to a group to which lot F does not belong. Switching from lot F, which is not in a group, to lot G requires a trolley change operation, and switching from lot G to lot H in the same group requires only internal setup work.

As described above, the management computer 3, which is equipped with the similarity rate calculation unit 30 and the production plan creation unit (leading plan creation unit 31), is a production plan creation system that creates a production plan for producing multiple types of mounted boards using multiple component mounting lines L1 to L3 equipped with component mounting devices M3 to M6. This makes it possible to automatically create the next production plan based on the current status of component mounting lines L1 to L3.

Next, following the flow of FIG. 11, a production planning method (production planning program) for creating a production plan for producing multiple types of mounted boards by component mounting lines L1 to L3 using management computer 3 (production planning system) will be described. In FIG. 11, first, leading plan creation unit 31 creates a leading plan that assigns leading production types to component mounting lines L1 to L3 (ST1: leading plan creation process). Next, group creation unit 36 calculates the commonality of planned production types 46b and creates groups (ST2: group creation process).

Then, the production plan update unit 37 creates a production plan in which the planned production types 46b, excluding the leading production type, are assigned to the leading plan so that a group is formed if a group is created (ST3: production plan update process). Next, the equipment configuration creation unit 32 creates the configuration of component mounting devices M3 to M6 when producing each planned production type 46b, based on the order of the created production plans (ST4: first equipment configuration creation process). Next, the switching time calculation unit 33 calculates the switching time for changing the configuration of component mounting devices M3 to M6 for the next production type in component mounting lines L1 to L3 (ST5: first switching time calculation process).

In FIG. 11, the cycle time calculation unit 35 then calculates the cycle time for producing the planned production type 46b on each of the component mounting lines L1 to L3 (ST6: first cycle time calculation process). Next, the predicted time calculation unit 38 calculates the predicted production completion time of the planned production type 46b, including the changeover time, based on the created production plan (ST7: predicted production completion time calculation process). Next, the delay determination unit 39 determines whether the calculated predicted production completion time has delayed the production due date 45 for all planned production types 46b (ST8: delay determination process).

If there is a planned production variety 46b whose predicted production completion time will delay the production due date 45 (Yes in ST8), the process returns to the group creation process (ST2) and the production plan update process (ST3) is executed. That is, if the predicted production completion time will delay the production due date 45, the allocation of the planned production variety 46b in the production plan to the component mounting lines L1 to L3 or the production sequence of the planned production variety 46b is changed in the production plan update process (ST3). In other words, the allocation of the leading production variety (leading plan) is not changed, but the allocation of the planned production variety 46b other than the leading production variety to the component mounting lines L1 to L3 and the production sequence are changed.

In FIG. 11, if all planned production types 46b (production types to be produced in the future) meet the production due date 45 in the delay determination process (ST8) (No in ST8), the production plan is stored in the production plan information 21a (ST9: production plan storage process), and the production plan creation is completed.

Next, the details of the leading plan creation process (ST1) will be described according to the flow in FIG. 12. In the leading plan creation process (ST1), first, the information acquisition unit 28 acquires the configuration of the production equipment of the component mounting lines L1 to L3 contained in the line configuration information 23a (ST11: line configuration information acquisition process). Next, the information acquisition unit 28 acquires the current configuration of the component mounting devices M3 to M6 equipped on the multiple component mounting lines L1 to L3 contained in the equipment configuration information 24b (ST12: current equipment configuration information acquisition process).

Then, the information acquisition unit 28 acquires information on the production variety to be produced (planned production variety 46b) contained in the production plan information 21a and variety information 21b (ST13: variety information acquisition process). In the variety information acquisition process (ST13), information on the production volume (production number 43) and production delivery date 45 of the planned production variety 46b is also acquired. Next, the range setting unit 29 displays a changeable range setting screen 47 (see FIG. 8) on the display unit 26, and sets the range in which the configuration of the component mounting devices M3 to M6 can be changed from the current configuration when producing the planned production variety 46b (ST14: changeable range setting process).

In FIG. 12, the similarity rate calculation unit 30 then calculates the similarity rate 52 between the planned production type 46b and the mounting boards that can be produced by the current configuration of the component mounting devices M3 to M6 (ST15: similarity rate calculation process). Next, the leading plan creation unit 31 creates a leading plan (production plan) in which the planned production type 46b is assigned to the multiple component mounting lines L1 to L3 in descending order of similarity rate 52 (ST16: leading lot assignment process). If a lower limit of the similarity rate 52 is set as the changeable range in the changeable range setting process (ST14), and the planned production type 46b that satisfies the similarity rate 52 cannot be assigned as the leading production type to all of the component mounting lines L1 to L3 (No in ST17), the process returns to the changeable range setting process (ST14) and the changeable range is reviewed.

When the leading production variety is assigned to all component mounting lines L1-L3 (Yes in ST17), the equipment configuration creation unit 32 then creates a configuration for component mounting devices M3-M6 for producing the leading production variety on component mounting lines L1-L3 (ST18: second equipment configuration creation process). Next, the switching time calculation unit 33 calculates the switching time required to change the configuration of component mounting devices M3-M6 from the current configuration to that for the leading production variety (ST19: second switching time calculation process). Next, the condition determination unit 34 determines whether the switching to the configuration for the leading production variety satisfies the changeable range (number of replacement feeders, work time, etc.) (ST20: condition determination process).

In FIG. 12, if the changeable range is not met (No in ST20), the process returns to the changeable range setting process (ST14) and the changeable range is reviewed. If the changeable range is met (Yes in ST20), the cycle time calculation unit 35 calculates the cycle time of the leading production variety (ST21). Next, the leading plan is stored in the production plan information 21a (ST22: leading plan storage process). This allows a production plan to be automatically created that changes the configuration of component mounting lines L1-L3 by switching the changeable range when starting the next production plan from an already created production plan, allowing production of the leading production variety to begin early.

As described above, the production plan creation method of this embodiment acquires the current configuration (equipment configuration information 24b) of component mounting devices M3-M6 equipped on component mounting lines L1-L3 (ST12), and acquires information on the planned production type 46b (production type to be produced in the future) (ST13). Then, a similarity rate 52 between the planned production type 46b and the mounting boards that can be produced in the current configuration of component mounting devices M3-M6 is calculated (ST15), and a production plan is created in which the planned production type 46b is assigned to multiple component mounting lines L1-L3 based on the similarity rate 52 (ST16). This makes it possible to automatically create the next production plan based on the current status of component mounting lines L1-L3.

The production planning method, production planning system, and production planning program of the present invention have the effect of being able to create the next production plan based on the current status of the component mounting line, and are useful in the field of mounting components onto circuit boards.

3. Management computer (production planning system)
9 Tape feeder (parts supply device)
46b Planned production variety (production variety to be produced in the future)
B Board D Component L1-L3 Component mounting line M3-M6 Component mounting device

Claims (11)

1. A production plan creation method for creating a production plan for producing a plurality of production types of mounted boards by a component mounting line including a component mounting device that mounts components supplied by a component supply device onto a board, the production plan comprising:
the production plan allocates a plurality of production types to a plurality of component mounting lines,
acquiring current configurations of component mounting devices provided in a plurality of component mounting lines;
A process of acquiring information on the production varieties to be produced;
calculating a similarity rate between the production type to be produced and the production type that can be produced in a current configuration of the component mounting device;
creating a production plan in which the production variety to be produced in the future is assigned to any one of the component mounting lines based on the similarity rate. The production plan creation method according to claim 1, wherein in the step of creating the production plan, the production variety is assigned to the component mounting line under the condition that the configuration of the component mounting device is changed from the current configuration within a predetermined changeable range when producing the production variety. The production plan creation method according to claim 2, further comprising a step of setting the changeable range based on the number of the component supply devices arranged in the component mounting device. The production plan creation method according to claim 2, further comprising a step of setting the changeable range based on the number of workers who change the configuration of the component mounting device. The production planning method according to claim 2, further comprising a step of setting the changeable range based on the time required to change the configuration of the component mounting device. The production planning method according to claim 2, further comprising a step of setting the changeable range based on the production types that can be produced on the component mounting line. calculating a predicted production completion time of the production type based on the created production plan;
7. The production plan creating method according to claim 1, further comprising the step of changing a production sequence of the production type when the predicted production completion time will delay a production delivery date. The production planning method according to claim 7, further comprising a step of changing the allocation of the production type to the component mounting line when the predicted production completion time will delay the production delivery date. The method further includes a step of calculating a switching time for changing a configuration of the component mounting device to a configuration for a next production type in the component mounting line,
9. The production plan creating method according to claim 7, wherein the predicted production completion time of the production type is calculated including the switching time. A production plan creation system for creating a production plan for producing a plurality of production types of mounted boards by a plurality of component mounting lines each having a component mounting device that mounts components supplied by a component supply device onto a board, the production plan creation system comprising:
a similarity rate calculation unit that calculates a similarity rate between the production type to be produced and a production type that can be produced with the current configuration of the component mounting device provided in the component mounting line, based on information on the production type to be produced in the future and a current configuration of the component mounting device;
a production plan creation unit that creates a production plan in which the production variety to be produced in the future is assigned to any one of the multiple component mounting lines based on the similarity rate. A production plan creation program that causes a computer to execute creation of a production plan for producing a plurality of production types of mounted boards by a plurality of component mounting lines each having a component mounting device that mounts components supplied by a component supply device onto a board, the production plan creation program comprising:
Obtaining a current configuration of a component mounting device included in the component mounting line;
A step of acquiring information on the production variety to be produced;
calculating a similarity rate between the production type to be produced and the production type that can be produced in a current configuration of the component mounting device;
creating a production plan in which the production variety to be produced in the future is assigned to any one of the component mounting lines based on the similarity rate.