Board Work Machine Simulation to Calculate Feeder-Supply Downtime
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Solution Overview
Problem
The component mounter in a component mounting line may stop production to receive feeder supply from an exchanging robot, leading to production stop times that are not accurately accounted for.
Innovation Solution
A simulation device and method that calculates production stop times of board work machines due to wait times by simulating the operating status of board work machines and article moving devices, using a simulation section and calculation section to determine production stop times based on production plans and operational conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an exchanging robot supplies feeders to a component mounter, then automation of feeder supply is improved, but production stop time increases due to wait time during feeder exchange
Solution Approach 1:
The simulation device calculates and determines in advance the optimal timing for feeder exchange operations. By performing preliminary calculation of production stop times and scheduling feeder exchanges during natural pauses in the mounting cycle, the system minimizes production stop time while maintaining automation.
Solution Approach 2:
The simulation device provides feedback on production stop time calculations, allowing operators to adjust feeder exchange scheduling. This feedback mechanism enables continuous optimization of the automation system to reduce wait time while maintaining efficient feeder supply.
2Reliability
If feeder exchange operations are performed during production, then continuous supply of components is improved, but production stop time is not accurately accounted for
Solution Approach 1:
The simulation device acts as an intermediary between the feeder exchange system and production planning. It calculates and provides accurate production stop time data that bridges the gap between automated feeder supply operations and overall production scheduling, ensuring both continuous supply and accurate time accounting.
3Reliability
If the component mounter waits for feeder supply, then proper component availability is ensured, but productivity decreases due to production stops
Solution Approach 1:
The simulation device performs preliminary calculation of production stop times and uses this information to schedule feeder exchanges in advance. By determining the optimal timing beforehand, the system ensures component availability is maintained while minimizing the impact on productivity through strategic scheduling during natural production pauses.
Data Source
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AI summary
The simulation device includes a simulation section and a calculation section. A simulation section is configured to simulate an operating status of a board work machine configured to perform predetermined board work on a board and produce a board product, and an operating status of an article moving device configured to supply an article needed for production of the board product to the board work machine based on a production plan of the board product. A calculation section is configured to calculate a production stop time of the board work machine caused by a wait time from when production of the board product by the board work machine is stopped to when the article is supplied by the article moving device based on a result of simulation by the simulation section.