Batch Exchange Cart System for Component Mounting Line Changeover
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Solution Overview
Problem
Current component mounting line changeover processes require significant operator time for feeder and suction nozzle arrangement work, leading to lowered productivity, as they necessitate individual exchange work during changeover.
Innovation Solution
Implementing a component mounting line changeover support method that uses batch exchange units for feeders and suction nozzles, where setup information is memorized and used to decide and notify operators of optimal batch exchange unit combinations for post-changeover production, allowing batch exchange work only, thereby eliminating the need for individual feeder or nozzle exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batch exchange carts are used to exchange multiple feeders at once, then the work amount of feeder arrangement work is minimized, but changeover time is still increased due to necessary feeder arrangement work during changeover
Solution Approach 1:
The system performs preliminary actions by pre-arranging feeders on batch exchange carts before changeover. The computer calculates optimal feeder arrangements and prepares carts in advance, so that during actual changeover, only simple cart exchanges are needed without requiring operators to perform time-consuming feeder arrangement work during the changeover process itself.
Solution Approach 2:
The system enables self-service by automatically calculating optimal batch exchange cart combinations and feeder arrangements using a computer. This eliminates the need for operators to manually plan and arrange feeders during changeover, as the system independently performs the optimization and preparation work.
2Manufacturing precision
If operators perform individual feeder exchange work during changeover, then precise feeder arrangement is achieved, but changeover time increases significantly
Solution Approach 1:
The system merges multiple individual feeder exchange operations into a single batch exchange cart replacement operation. By combining all feeders needed for a product change onto pre-prepared batch exchange carts, the system performs one unified exchange action instead of multiple individual feeder swaps, maintaining arrangement precision while dramatically reducing changeover time.
Solution Approach 2:
The computer performs preliminary calculation and arrangement of feeders on batch exchange carts before changeover begins. This advance preparation ensures that when carts are exchanged during changeover, the feeders are already in their correct positions and arrangements, eliminating the need for time-consuming individual adjustment work during the actual changeover process.
3Ease of operation
If multiple batch exchange carts are prepared for exchange, then feeder arrangement work is reduced, but the complexity of managing multiple carts increases
Solution Approach 1:
The computer provides feedback by automatically calculating and determining the optimal combination of batch exchange carts based on the required feeders for the target product. The system analyzes the relationships between multiple carts and feeders, and provides optimized exchange plans to operators, reducing the complexity of managing multiple carts by providing clear, calculated guidance.
Solution Approach 2:
The system performs self-service by automatically managing the complexity of coordinating multiple batch exchange carts. The computer independently calculates optimal cart combinations, determines which carts to exchange, and provides structured exchange plans, eliminating the need for operators to manually manage the complexity of multiple cart coordinates and arrangements.
Data Source
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AI summary
A combination of batch exchange carts 18 that includes all of the feeders 17 that supply components to be used in the post-changeover production from the multiple batch exchange units 18 prepared in preparation space 25 is decided based on the component information of feeders 17 loaded on batch exchange carts 18 used in the pre-changeover production and setup information of batch exchange carts 18 that can be used for exchange memorized in memory device 23 (component information of feeders 17 loaded on batch exchange carts 18 in preparation space 25), and then an operator is notified of the decided combination of batch exchange carts 18 by sound or by the display of a mobile terminal or display device 24 of production management computer 21. Here, in a case in which there are multiple combinations of batch exchange units 18 that include all of the feeders 17 to be used in the post-changeover production, the production cycle time may be calculated for each of the combinations, and an optimal combination that is the combination with the shortest cycle time may be decided and notified to an operator via sound or display.