A production line balance analysis method to assist process route design

Abstract

The present invention relates to a production line balance analysis method for assisting process route design, belonging to the field of intelligent production, including: after the process route design is completed, using the production line balance analysis, that is, performing complex calculations on the man-hour information under the process route, combining the actual production rhythm, calculating the required number of work steps and the required reference materials under the work steps, and generating a columnar accumulation chart of the man-hours of the work steps and reference materials based on a given actual production line balance rate, which can clearly find the bottleneck process, and by adjusting the number of work steps and reference materials under the bottleneck process, the optimal allocation of the work step resources under the bottleneck process is achieved, and the reasonable design of the process route is completed. The present invention greatly improves the quality and one-time success rate of process route design.

Description

Technical Field

[0001] The invention relates to a production line balance analysis method for auxiliary process route design, belonging to the technical field of intelligent production. Background Art

[0002] Many companies, especially those in the electronics industry, adopt a multi-variety, small-batch product development model. This type of R&D model has the characteristics of product diversity, production complexity, production capacity adaptability, production cycle and order uncertainty, material demand and procurement management, production management and control, and market demand responsiveness. Companies can identify and eliminate unnecessary steps and waste, optimize work processes, and rationally allocate production resources such as equipment, personnel and materials to reduce waste caused by idle or excessive use of resources, reduce waiting time and stagnation on the production line, and reduce the labor consumption of a single product, thereby improving production efficiency and shortening the development cycle of electronic products. Only by having a high degree of flexibility and adaptability in the development process can companies cope with the ever-changing market demand and production environment.

[0003] Therefore, it is necessary to construct a production line balance analysis method to assist process route design. Summary of the invention

[0004] In order to solve the above problems, the present invention discloses a production line balance analysis method for auxiliary process route design, and its specific technical solution is as follows:

[0005] A production line balance analysis method for assisting process route design includes the following steps:

[0006] Step 1: According to the design requirements and production conditions of the product or component, complete the preliminary work of process route design, which includes the determination of the process route, equipment selection and layout, and production line planning; the process route is divided into multiple processes, and each process is divided into multiple steps;

[0007] Step 2: Automatically allocate materials for each process step according to the automatic allocation rules of the reference parts. After the materials are allocated, complete the working time parameter information of the process and steps under the process route. The working time parameter information includes material working time, operation working time and preparation working time.

[0008] Step 3: Gather the parameters of PCB panel order parameters B / T, PCB board quantity, and working time information under the process, use the production line balance analysis method to find the bottleneck process, and then calculate the required steps and the number of reference materials under the bottleneck process according to the calculation rules of the production line balance rate;

[0009] Step 4: Adjust the working steps and the quantity of materials to be loaded under the bottleneck process, recalculate the balance rate of the production line, and finally achieve a balance rate of more than 85%. The process route design is reasonable, and it is considered that the production line has achieved "one-flow" production.

[0010] Furthermore, the material working time W in step 2 物料 It refers to the working hours automatically calculated according to the information of the materials associated with each process. According to the fixed working hours M of the materials loaded under the process * the number of PCB boards N, it is: W 物料 =M*N.

[0011] Furthermore, the working hours W in step 2 are 作业 It is divided into processes with no loading materials and with the participation of automated equipment, and processes with no loading materials and no automated equipment:

[0012] a) For processes without reference materials and with automated equipment, the operation time is calculated according to the order of PCB depaneling, the number of PCB boards, and the corresponding parameter values ​​of the process coefficient as follows:

[0013] When the PCB board separation order is B, that is, single-sided operation, the operation time is W 作业 Use W 作业B Indicates that the working hours W 作业B = PCB number * board order coefficient * process coefficient, that is, W 作业B =N*0.4*β;

[0014] When the PCB board separation order is T, that is, double-sided operation, the operation time is W 作业 Use W 作业T Indicates that the working hours W 作业T = PCB board quantity * board order coefficient, that is, W 作业T =N*0.8*β;

[0015] b) For processes without any materials, semi-automatic or manual operation, and processes without the participation of automated equipment, a fixed working time value will be allocated to each process based on actual production.

[0016] Furthermore, the preparation time R in step 2 is: the compensation time required in addition to the material time and operation time, according to the fixed value of the given process.

[0017] Furthermore, the step three is specifically as follows:

[0018] Step 3.1: Calculate the total working time information of each process under the process through the PCB depaneling sequence parameter B / T under the process, the process and process parameters of the number of PCB boards N;

[0019] Step 3.2: According to the electrical process and process parameters, the total process time is calculated according to material time, operation time, and preparation time. The total process time H = material time + operation time + preparation time, that is: H = W 物料 +W 作业 +R,W 作业 Take W according to the PCB board separation order parameter B / T 作业B or W 作业T .

[0020] Furthermore, the specific process of step 4 is as follows:

[0021] 4.1) From step 3, the maximum total working time required for each process under the process is obtained. Since the process with the longest working time under the process determines the operation time of the entire production line, that is, the production cycle, according to the calculation formula of the production line balance rate

[0022] ,

[0023] When the production line balance rate is greater than or equal to 85%, the number of steps in the process is used as the input variable, and the production line balance rate is calculated by the number of processes;

[0024] 4.2) According to the number of work steps in the process, combined with the type of materials that need to be loaded under the process and the sequence of work steps, the work steps under the plug-in process are automatically generated and the materials are automatically allocated. According to the actual situation, the automatically generated work steps and allocated materials are manually adjusted to achieve a reasonable allocation of work steps and materials under the process.

[0025] The working principle of the present invention is:

[0026] After the process route design is completed, the present invention can use production line balance analysis, that is, to perform complex calculations on the working time information under the process route, and after combining the actual production rhythm, deduce the required number of working steps and the required reference materials under the working steps, and then generate a columnar accumulation chart of the working time of the working steps and the reference materials based on a given actual production line balance rate, which can very clearly find the bottleneck process, and through the adjustment of the number of working steps and the reference materials under the bottleneck process, the optimal allocation of working step resources under the bottleneck process is achieved, the reasonable design of the process route is completed, and the quality of the process route design and the one-time success rate are greatly improved.

[0027] The beneficial effects of the present invention are:

[0028] The present invention is a technical means and method that analyzes the load of all processes in the production line and adjusts the load distribution between processes to achieve capacity balance (operation time is as close as possible) in each process, thereby achieving balanced resource allocation under the optimal working step of the bottleneck process under a specific line balance rate. Its ultimate goal is to eliminate various waiting waste phenomena and improve the overall efficiency of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the process of the present invention,

[0030] Figure 2 is a process flow chart of an embodiment of the present invention,

[0031] Figure 3 It is a graphical display diagram of production line balance analysis according to an embodiment of the present invention. DETAILED DESCRIPTION

[0032] The present invention is further explained below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention.

[0033] Combined with Figure 1 It can be seen that the production line balance analysis method of the auxiliary process route design includes the following steps:

[0034] Step 1: According to the design requirements and production conditions of the product or parts, complete the preliminary work of process route design, such as process route determination, equipment selection and layout, and production line planning;

[0035] Step 2: Automatically allocate materials for each process step according to the automatic allocation rules of the reference parts. After the materials are allocated, complete the working time parameter information of the process steps under the process route. The working time parameter information includes material working time, operation working time, and preparation working time.

[0036] 1) Material working hours W 物料 :The working hours automatically calculated according to the information of the materials associated with each process, according to the fixed working hours M of the materials loaded under the process * the number of PCB boards N, that is: W 物料 =M*N, taking the process flow chart as an example, the material loading process and material fixed working hours are as shown in Table 1:

[0037] Table 1

[0038]

[0039] 2) Working hours W 作业 : It can be divided into processes with no loading materials and with the participation of automated equipment and processes with no loading materials and no automated equipment:

[0040] a) For processes without reference materials and with automated equipment, the operation time can be calculated according to the order of PCB depaneling, the number of PCB boards, and the corresponding parameter values ​​of the process coefficient as follows:

[0041] When the PCB depaneling order is B (single-sided operation), the operation time is W 作业B= PCB number * board order coefficient * process coefficient, that is, W 作业B =N*0.4*β; the calculation example is as shown in Table 2:

[0042] Table 2

[0043]

[0044] When the PCB depaneling sequence is T (double-sided operation), the operation time is W 作业T = PCB board quantity * board order coefficient, that is, W 作业T =N*0.8*β; the calculation example is as shown in Table 3:

[0045] Table 3

[0046]

[0047] For processes without loading materials, semi-automatic or manual operations, and processes without automated equipment, fixed operation hours can be allocated to each process based on actual production conditions; an example calculation is shown in Table 4:

[0048] Table 4

[0049]

[0050] 4) Preparation time R: The compensation time required in addition to material time and operation time, generally based on a fixed value for a given process, for example Figure 2 Taking the flowchart as an example, the preparation time R of each process is shown in the following table: Example calculation is shown in Table 5:

[0051] Table 5

[0052]

[0053] Step 3: Gather the parameters such as PCB depaneling sequence parameters B / T, PCB single board quantity, working time information, etc. under the process, use the production line balance analysis method to find out the bottleneck process, and then calculate the required steps and the number of reference materials under the bottleneck process according to the calculation rules of the production line balance rate;

[0054] 1) Calculate the total working hours of each process under the process through the process parameters such as the PCB panel separation sequence parameter B / T and the number of PCB boards N; Taking the common SMT process as an example, the process includes material preparation, BOT surface solder paste printing, BOT surface patch, BOT surface reflow soldering, TOP surface solder paste printing, TOP surface patch, TOP surface reflow soldering, process inspection, manual plug-in, wave soldering, cleaning, crimping, inspection, and packaging.

[0055] 2) According to the electrical process and process parameters, the total process time is calculated according to material time, operation time and preparation time. The total process time H = material time + operation time + preparation time, that is: H = W 物料 +W 作业 +R,W 作业 Take W according to the PCB board separation order parameter B / T 作业B or W 作业T , according to the process Figure 2 For example, the PCB sequence is Class B, and the total working hours for each process are calculated as shown in Table 6:

[0056] Table 6

[0057]

[0058] Step 4: Adjust the working steps and the quantity of materials to be loaded under the bottleneck process, recalculate the balance rate of the production line, and finally increase the balance rate of the production line to more than 85%. The process route is designed reasonably, and it can be considered that the production line has basically achieved "one-flow" production.

[0059] From Table 6 above, it can be concluded that the total working time required for the plug-in welding process under the process is the largest, and the total working time of the process is 198s. Since the process with the longest working time under the process determines the operation time of the entire production line, it is the production cycle.

[0060] a) According to the calculation formula of production line balance rate

[0061]

[0062] b) When the balance rate of the production line is greater than or equal to 85%, the number of steps in the plug-in welding process (one operator for each step) is used as the input variable, and the calculation list is shown in Table 7 through the enumeration value of the number of steps:

[0063] Table 7

[0064]

[0065] c) Through the above calculation, it can be known that when the number of plug-in steps is 4, the production line balance is greater than or equal to 85%.

[0066] According to the number of work steps of the plug-in welding process recommended in the steps, combined with the types of materials that need to be loaded under this process and the sequence of work steps, the work steps under the plug-in process are automatically generated and the materials are automatically allocated. The automatically generated work steps and allocated materials can be manually adjusted according to the actual situation to achieve a reasonable allocation of work steps and materials under the plug-in welding process.

[0067] Figure 3It is a screenshot of the interface of the statistical bottleneck process when the present invention is used, which is convenient for intuitively checking the bottleneck process, and then convenient for adjusting the personnel or materials of the process, which is the production process, avoiding slowness of some links and affecting the overall efficiency.

[0068] It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as generally understood by those skilled in the art to which this application belongs. It should also be understood that terms such as those defined in common dictionaries should be understood to have meanings consistent with the meanings in the context of the prior art, and will not be interpreted with idealized or overly formal meanings unless defined as herein.

[0069] Based on the above ideal embodiments of the present invention, the relevant staff can make various changes and modifications without departing from the technical concept of the present invention through the above description. The technical scope of the present invention is not limited to the contents of the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A production line balance analysis method for assisting process route design, characterized in that: The following steps are involved: Step 1: According to the design requirements and production conditions of the product or component, complete the preliminary work of process route design, which includes the determination of the process route, equipment selection and layout, and production line planning; the process route is divided into multiple processes, and each process is divided into multiple steps; Step 2: Automatically allocate materials for each process step according to the automatic allocation rules of the reference parts. After the materials are allocated, complete the working time parameter information of the process and steps under the process route. The working time parameter information includes material working time, operation working time and preparation working time. Material working time W 物料 It refers to the working hours automatically calculated according to the information of the materials associated with each process. According to the fixed working hours M of the materials loaded under the process * the number of PCB boards N, it is: W 物料 =M*N; Working hours W 作业 It is divided into processes with no loading materials and with the participation of automated equipment, and processes with no loading materials and no automated equipment: a) For processes without reference materials and with automated equipment, the operation time is calculated according to the order of PCB depaneling, the number of PCB boards, and the corresponding parameter values ​​of the process coefficient as follows: When the PCB board separation order is B, that is, single-sided operation, the operation time is W 作业 Use W 作业B Indicates that the working hours W 作业B = PCB number * board order coefficient * process coefficient, that is, W 作业B =N*0.4*β; When the PCB board separation order is T, that is, double-sided operation, the operation time is W 作业 Use W 作业T Indicates that the working hours W 作业T = PCB board quantity * board separation order coefficient * process coefficient, that is, W 作业T =N*0.8*β; b) For processes without any materials, semi-automatic or manual operation, and processes without the participation of automated equipment, a fixed working time value shall be allocated to each process according to actual production; Preparation time R: the compensation time required in addition to material time and operation time, which is given as a fixed value for the process; Step 3: Gather the parameters of PCB panel order parameters B / T, PCB single board quantity, and working time information under the process, use the production line balance analysis method to find the bottleneck process, and then calculate the required steps and the number of reference materials under the bottleneck process according to the calculation rules of the production line balance rate; specifically: Step 3.1: Calculate the total working time information of each process under the process through the PCB depaneling sequence parameter B / T under the process, the process and process parameters of the number of PCB boards N; Step 3.2: According to the electrical process and process parameters, the total process time is calculated according to material time, operation time, and preparation time. The total process time H = material time + operation time + preparation time, that is: H = W 物料 +W 作业 +R,W 作业 Take W according to the PCB board separation order parameter B / T 作业B or W 作业T ; When the maximum total working hours required for each process under the process are obtained, the production line balance rate is calculated according to the production line balance rate calculation formula: ； Step 4: Adjust the working steps and the quantity of materials to be loaded under the bottleneck process, recalculate the balance rate of the production line, and finally achieve a balance rate of more than 85%. The process route design is reasonable, and it is considered that the production line has achieved "one-flow" production.

2. The production line balance analysis method for auxiliary process route design according to claim 1 is characterized in that: The specific process of step 4 is as follows: 4.1) Since the longest working time in the process determines the operation time of the entire production line, that is, the production cycle, when the production line balance rate is greater than or equal to 85%, the number of steps in the process is used as the input variable, and the production line balance rate is calculated by the number of processes; 4.2) According to the number of work steps in the process, combined with the type of materials that need to be loaded under the process and the sequence of work steps, the work steps under the plug-in process are automatically generated and the materials are automatically allocated. According to the actual situation, the automatically generated work steps and allocated materials are manually adjusted to achieve a reasonable allocation of work steps and materials under the process.

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