Assembly Line Module Assignment for Fixed-Setup Capacity Balancing
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Solution Overview
Problem
Existing methods for determining module assignments on assembly lines in electronics production do not efficiently account for matching multiple assembly lines to produce different circuit board types, leading to unproductive waiting times and high setup expenses due to varying cycle times and batch sizes.
Innovation Solution
A computer-implemented method using mixed-integer linear programming to optimize the assignment of module types to assembly lines, considering cycle times and component types, to minimize production time and setup costs by forming fixed-setup setup families.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If modules are produced in commissions with fixedly predefined batch sizes, then setup expense is reduced, but productivity decreases due to larger batch sizes and longer lead times
Solution Approach 1:
The patent applies dynamics by enabling assembly lines to switch between fixed and variant setup modes. Priority lines operate with fixed setups for cost efficiency, while normal lines use variant setups for flexibility. The system dynamically assigns module types to appropriate line types based on real-time production requirements, allowing the manufacturing system to adapt its operational mode rather than being locked into a single batch size approach.
Solution Approach 2:
The patent changes the parameter of batch size from fixed to variable by introducing two types of assembly lines with different setup characteristics. This allows the system to adjust batch sizes according to module type and production priorities, rather than being constrained to uniform batch sizes across all production scenarios.
2Productivity
If multiple assembly lines are used to produce different circuit board types, then productivity increases, but unproductive waiting times occur due to mismatched cycle times
Solution Approach 1:
The patent applies local quality by assigning different operational characteristics to different assembly lines based on their roles. Priority lines are optimized for high-capacity fixed setup production, while normal lines are optimized for flexible variant setup production. Each line type is locally optimized for its specific function, and the control system intelligently distributes module types to appropriate lines to minimize waiting times caused by cycle time mismatches.
3Adaptability or versatility
If setup tables are interchanged easily on assembly machines, then adaptability increases, but refilling complexity increases
Solution Approach 1:
The patent segments the setup system into two distinct types: fixed setups for priority lines and variant setups for normal lines. This segmentation allows each type to be optimized independently—fixed setups minimize refilling operations by maintaining stable component configurations, while variant setups provide adaptability for different module types. The segmentation resolves the contradiction by allowing the system to choose the appropriate setup type based on production requirements.
4Ease of manufacture
If priority lines operate with fixed setups, then setup expense decreases, but production flexibility decreases
Solution Approach 1:
The patent creates a universal manufacturing system where both fixed and variant setup lines coexist and can handle different module types. The control system universally manages the assignment of module types to appropriate line types, allowing the overall system to achieve both cost efficiency through fixed setups and flexibility through variant setups. Each line type serves its specialized function while contributing to the universal capability of the entire manufacturing system.
Data Source
AI summary
A method for determining an optimum assignment of module types including:a) ascertaining an expected production time for each module type of the modules to be assembled and for each assembly line;b) assigning a set of module types of the set of module types to a predefined number of fixed-setup setup families containing respectively associated fixed setups;c) optimizing the assignment from b) such that, for all module types that are assigned to the fixed-setup setup families, a sum of differences between the expected production time per module type, if it were to be assembled on one of the remaining assembly lines with the minimum production time out of the at least one remaining assembly line, and the expected production time on the selected assembly line is maximized; andd) outputting the optimized assignment in a form suitable for controlling and/or regulating the assembly of the modules.