Automatic Feeder Arrangement Support for Component Shortage Prevention
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Solution Overview
Problem
In component mounting lines, manual feeders often lead to production inefficiencies due to human errors in splicing and replenishing component supply tapes, resulting in component shortages and line stoppages, despite the introduction of automatic feeders which can automate replenishment but are not optimally utilized in planning.
Innovation Solution
An automatic feeder arrangement support system that includes a component shortage time calculation section and a detection section to simulate and detect component shortages, allowing for the strategic replacement of manual feeders with automatic feeders to prevent shortages and optimize feeder arrangement based on production plans and actual production status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual feeders are used for component replenishment, then flexibility in operation is maintained, but component shortages occur due to human errors in splicing and replenishing
Solution Approach 1:
The automatic feeder replenishes component supply tapes automatically without human intervention. The system detects when a tape is nearly exhausted and autonomously replaces it with a new tape, eliminating manual splicing operations and associated human errors while maintaining continuous component supply.
Solution Approach 2:
The patent replaces manual mechanical splicing operations with an automated feeder mechanism. The automatic feeder uses mechanical automation to perform tape replacement, substituting human hands and tools with a controlled mechanical system that operates precisely and consistently.
2Productivity
If automatic feeders are introduced to automate replenishment, then work efficiency increases, but optimal utilization in planning is reduced
Solution Approach 1:
The system incorporates a simulation calculation function that monitors component consumption rates and predicts future shortages. This feedback mechanism provides advance warning to planners about which automatic feeders will need replenishment, enabling optimized planning despite the complexity of managing multiple automatic feeders.
Solution Approach 2:
The patent performs simulation calculations in advance to predict component shortages before they occur. By calculating expected consumption based on production plans and detecting potential shortages提前, the system enables proactive planning and arrangement optimization of automatic feeders before actual replenishment is needed.
3Loss of time
If component replenishment is delayed until normal warning, then response time is reduced, but component shortages occur before replenishment completes
Solution Approach 1:
The simulation calculation function performs advance detection of component shortages by predicting when supplies will be exhausted based on current consumption rates. This preliminary detection triggers early warning before actual shortage occurs, allowing replenishment to be initiated with sufficient time margin to complete before production is affected.
Solution Approach 2:
The system continuously monitors component consumption and provides feedback through simulation calculations. This real-time feedback mechanism adjusts replenishment timing dynamically, warning operators or automatic systems in advance of predicted shortages, enabling optimal replenishment scheduling that prevents shortages while minimizing unnecessary early replenishment.
Data Source
AI summary
An automatic feeder arrangement support system is in a component mounting line including a component mounting device that includes a component supply device and a mounting head configured to pick up components from component supply tapes and mount the components on a substrate. The automatic feeder arrangement support system includes a component shortage time calculation section and a component shortage detection section. The component shortage time calculation section is configured to calculate component shortage time data based on production plan data and substrate data related to substrate. The component shortage detection section is configured to perform a simulation and detect whether component shortage occurs or not based on the component shortage time data and workable time data for a replenishment work of manual feeders.