Patent Application
20090118856
The instant nonprovisional patent application claims priority to Japanese Patent Application No. 2007-261116 filed Oct. 4, 2007 and which is incorporated by reference in its entirety herein for all purposes.
In mass-production manufacturing of home electronics, semiconductor devices, magnetic storage devices, printed circuit boards, etc., automated manufacturing systems such as robots and machine tools may perform manufacturing by treatment with chemical reaction, microfabrication, microassembly, or the like because it is difficult for workers to conduct operation directly. In the automated manufacturing systems, robots and machine tools may conduct main operations and workers may conduct supplementary operations such as carrying in and carrying out of works and setup operations.
For example, in manufacturing of magnetic storage devices, products are completed in the following manner: assembly operation of a plurality of magnetic heads and magnetic disks with other parts such as spindle motors and frames is conducted by a special robot system; the assembled works are collected and transported by workers to the testing process as a subsequent process; and then, the magnetic characteristics and storage capacity of the works are tested by automated equipment.
Further, in printed circuit boards, products are completed in the following manner: minute electronic parts such as semiconductor chips and capacitors are arranged on printed circuit boards by an automatic machine and automatically bonded and cured in a solder reflow furnace; then, the printed circuit boards are collected and transported by workers to the testing process as a subsequent process; and electric tests are conducted by an automatic machine.
In the above described manufacturing, raising productivity of the automated manufacturing system is an important challenge in view of investment recovery. Assuming that the improvement in productivity is defined as production output per unit time, reduction of main operation time and reduction of supplementary operation time must be achieved for improvement in productivity. Especially, in the automated manufacturing system, there is an important challenge in reducing supplementary operation time including reducing failure frequency, setup operation time, waiting time for the works to stay until the works can be carried into the process, and the like.
For example, in manufacturing of magnetic storage devices, their magnetic characteristics and storage capacity may be tested by plural continuous automated manufacturing systems. For the test, conventionally, there has been a batch operation method of inputting a batch of several tens to several hundreds of magnetic storage devices to a testing device and conducting a test thereon, and inputting the batch to a testing device in the next process conducting a test thereon. In this regard, there has been (1) a problem of magnetic storage device characteristics that even magnetic devices having the same capacity need different test times due to individual performance difference in reading and writing, and (2) an operation problem that the magnetic storage devices can not be carried out until the test of a predetermined amount or more of them relative to the entire number of magnetic storage devices have been finished. Because of the problems (1) and (2), when workers should go to the testing device and conduct, operation is unpredictable and the magnetic storage devices wait for being carried out within the testing device after the test is finished, and therefore, there has been a problem that supplementary operation time becomes longer and the problem causes inhibition of improvement in productivity of the automated manufacturing system.
Further, there is an individual operation method of inputting magnetic storage devices one by one to a testing device and conducting a test thereon, and inputting them one by one to a testing device in the next process and conducting a test thereon other than the above described batch operation method. Furthermore, there is an automated manufacturing system containing a collection of several tens to several thousands of testing devices and transporting magnetic storage devices one by one with a robot handler and conducting tests using the method. In the automated manufacturing system, when an exceptional operation such as system emergency stop is conducted, the restoration procedure varies depending on the test progress statuses of the individual magnetic storage devices. On the other hand, because of the above described problem (1), unless the test times of the individual magnetic storage devices are constantly recognized, there is a problem the restoration operation takes time and the supplementary operation time becomes longer and the problem causes inhibition of improvement in productivity of the automated manufacturing system.
As described above, to reduce the supplementary operation time, an important challenge is to constantly recognize the manufacturing progress of individual works in the process and when, where, and what operations should be conducted by workers can be predicted depending on the statuses. Regarding the challenge, Japanese Patent Publication No. 2007-18447 (“Patent Document 1”) proposes a method of indicating the test progress statuses of magnetic storage devices with lighting indicators provided in the respective testing devices. Japanese Patent Publication No. 2007-122251 (“Patent Document 2”) proposes a method of collectively managing the progress information of recording medium creating processing of magnetic storage devices with a computer, and indicating the progress statuses in colors or textures on representation that reproduces the shape of the recording media on the indicator of the computer is proposed. Further, Japanese Patent Publication No. 2002-366222 (“Patent Document 3”) proposes a method of predicting the time to be taken for measurement tests by comparing, with respect to the progress statuses of the wafer measurement tests, the ratio of acceptable chips (yield) within a wafer in the process and the measurement time that has been taken so far with the past measurement test records, and using the time for making the schedule of the entire production system.
In the above described patent document 1, there is a problem that the status can not be recognized unless workers see around the individual testing devices. Especially, in a production site in which several thousands of devices are provided in parallel, there is a problem determining which device is under what condition of the progress status.
Further, in the patent document 2, there is a problem that no specific indicating means for indicating the location within the production site in block number. Especially, in a production site in which several thousands of devices are provided in parallel, there is a problem determining which device is under what condition of the progress status.
In the patent document 3, there is a problem that instructions can not be given to workers in advance when to conduct setup for operation after completion of processing of devices. The setup here includes an operation of confirming whether works can be input to the next process of the test process of interest, an operation of collecting and carrying in the next works to be input. There is a challenge that these setup operations are started at appropriate times and the next operations are immediately conducted when the tests are completed for suppressing the extension of the supplementary operation time.
Embodiments of the present invention provide a method and system for solving a location designation problem to give specific instructions to workers as to where the device that has completed processing is in the production site, and a setup starting time designation problem to give instructions to workers as to when the setup for operation after a test is completed is conducted.
As shown in
Embodiments of the present invention provide a method and system for improvement in production efficiency for mass-production manufacturing of home electronics, semiconductor devices, magnetic storage devices, printed circuit boards, etc.
Embodiments of the invention are capable of raising productivity of an automated manufacturing system, focuses its attention on reduction of supplementary operation time, and provides a status indication technology of devices to solve (A) location designation problem to give specific instructions to workers as to where the device that has completed processing is in the production site, and (B) setup starting time designation problem to give instructions to workers when to conduct the setup for operation after a test is completed.
A representative status indication method of embodiments of the invention is a status indication method for managing a starting time of a setup operation in an automated manufacturing system in which setup of a plurality of devices placed in a production site is conducted by a worker or an automatic machine, and includes:
the step of recognizing locations within the production site and processing progress statuses from said plurality of devices;
the step of indicating the locations and the processing progress statuses of the plurality of devices recognized in said step;
the step of predicting starting times of the setup operation for an operation after processing is completed from the processing progress statuses of said plurality of devices recognized in said step; and
the step of indicating the starting times of the setup operation predicted at said step.
According to embodiments of the invention, since an instruction as to where the device in which processing is completed is in the production site can be given to the worker, the worker can reach the device to be operated without getting lost, and finish the setup at the time when the processing of the device is completed and immediately carry out the completely processed works and carry in new works. Therefore, the supplementary operation time can be reduced and the reduction contributes to improvement in productivity of the automated manufacturing system.
First, a schematic procedure of embodiments of the invention will be described with reference to
In embodiments of the invention, means (104) for recognizing the processing progress statuses of the devices (103) in the production site (101), means (105) for indicating the processing progress statuses of the devices, means (106) for predicting the processing completion times of the devices, and means (107) for indicating when a preparation (setup operation) are started for which devices are provided. A worker (108) receives the processing progress statuses of the respective devices (103) of the respective units (102) from the means (105) for indicating the processing progress statuses of the devices, and records the times to carry in the works (109) to be placed in the devices (103) with a cart (110) to the devices (103) and start placement from the means (107) for indicating when a setup operation is started for which device.
That is, carrying in and carrying out of the works (109) to the devices (103) can be performed in synchronization with the processing completion times by the means (107) for indicating when a setup operation is started for which device, and the location where a work in which device (103) of which unit (102) is carried out and a new work (109) is carried in and placed can be known by the means (105) for indicating the processing progress statuses of the devices, and thus, supplementary operation time can be reduced.
A plurality of units (203) are provided in process 1, and a plurality of devices (204) are provided in each unit (203). Here, the devices (204) in which works are placed are shown by squares with grid pattern, and devices (205) without works in the idol state are shown by black squares. The works are placed in the devices (204) in terms of the units (203) and the works are carried out from the devices (204) in terms of the units (203). That is, when processing is completed in one device but not completed in another device within the same unit, the completely processed work can not be carried out from the device but wait for being carried out.
Similarly, a plurality of units (208) are provided in process 2, and a plurality of devices (209) are provided in each unit (208). Here, the devices (209) in which works are placed are shown by squares with grid pattern, and devices (210) without works in the idol state are shown by black squares. The works are placed in the devices (209) in terms of the units (208) and the works are carried out from the devices (209) in terms of the units (208). That is, when processing is completed in one device but not completed in another device within the same unit, the completely processed work can not be carried out from the device but wait for being carried out.
According to the instruction, the worker (X06) transports HDDs to be newly tested from HDDs in process (X07) to the test unit 1-b (X09), takes out the completely processed HDDs, and places the HDDs to be newly tested. The setup operation including transportation, taking out, and placement takes time. Conventionally, the setup operation is started at the time when the test unit 1-b (X09) is ended, for example, and the test unit 1-b (X09) waits for the completion of the setup operation in the setup operation time, and thereby, the productivity is lowered. On the other hand, in an embodiment of the invention, the test ending time is predicted, the setup starting time is predicted therefrom, and then, the setup operation is started. Therefore, the test unit 1-b (X09) does not need to wait for the completion of the setup operation, and the productivity is no longer lowered.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-261116 | Oct 2007 | JP | national |
