Circuit Board Assignment Optimization Using Mixed Integer Programming
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Solution Overview
Problem
In circuit board manufacturing, existing methods face challenges in efficiently assigning and optimizing the production of circuit boards between fixed equipment and variant equipment setups, leading to increased planning and setup efforts, reduced productivity, and frequent refitting needs.
Innovation Solution
A method for determining fixed equipment setups by assigning circuit board types based on predetermined criteria, such as order frequency and production times, using mixed integer programming to optimize the assignment quality and reduce setup efforts, while ensuring efficient use of shuttle tables and minimizing refitting frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If circuit boards are produced using variant manufacturing with frequent setup family changes, then manufacturing flexibility is maintained, but planning effort, setup effort, and refitting frequency increase
Solution Approach 1:
The patent segments circuit boards into different manufacturing categories (fixed equipment manufacturing vs. variant manufacturing) based on their characteristics and production volumes. This segmentation allows each segment to be optimized independently, with high-volume boards assigned to fixed equipment and low-volume boards to variant manufacturing, thereby reducing overall setup and planning efforts while maintaining necessary flexibility.
Solution Approach 2:
The patent performs preliminary assignment of circuit boards to fixed equipment or variant manufacturing categories before production begins. By analyzing board characteristics, component requirements, and production volumes in advance, the system determines the optimal manufacturing approach for each board type, preventing frequent mid-production changes and reducing setup efforts.
2Productivity
If fixed equipment manufacturing is increased to reduce setup effort, then productivity improves, but equipment complexity and initial setup requirements increase
Solution Approach 1:
The patent creates a unified manufacturing system that can handle both fixed equipment manufacturing and variant manufacturing through the same populating line. The system universally processes all circuit board types by automatically determining the appropriate manufacturing approach, eliminating the need for separate production lines and reducing overall equipment complexity while maintaining high productivity for suitable board types.
Solution Approach 2:
The patent changes the operational parameters of the populating line dynamically based on the circuit board being processed. By adjusting parameters such as equipment assignment, component selection, and production mode (fixed vs. variant) according to board characteristics and production volumes, the system achieves high productivity without requiring permanently complex equipment configurations.
3Duration of action of stationary object
If shuttle tables are permanently equipped for fixed equipment manufacturing, then refitting frequency decreases, but initial equipment configuration time and complexity increase
Solution Approach 1:
The patent implements a dynamic equipment assignment system where shuttle tables are assigned to fixed or variant manufacturing based on real-time analysis of production requirements. Rather than permanently configuring shuttle tables, the system dynamically determines the optimal manufacturing approach for each circuit board, allowing shuttle tables to be reused flexibly while maintaining long usage durations for fixed equipment assignments.
Solution Approach 2:
The patent performs preliminary analysis of circuit board requirements and production volumes to determine optimal shuttle table assignments before production begins. This advance planning allows shuttle tables to be configured for long-duration fixed equipment manufacturing when appropriate, reducing refitting frequency while avoiding unnecessary initial configuration complexity through data-driven decision-making.
4Loss of time
If more circuit board types are assigned to fixed equipment setup families, then setup effort is reduced, but the ability to handle variant manufacturing requirements decreases
Solution Approach 1:
The patent segments the circuit board portfolio into fixed equipment manufacturing and variant manufacturing categories based on objective criteria such as production volume, board complexity, and component variety. This segmentation ensures that only boards suitable for fixed equipment manufacturing are assigned to those setup families, preventing over-assignment that would compromise variant manufacturing capability while still maximizing the benefits of reduced refitting time for appropriate boards.
Solution Approach 2:
The patent uses parameter-based decision-making to assign circuit boards to manufacturing categories. By evaluating multiple parameters (production volume, board type, component requirements) and changing the manufacturing approach parameter accordingly, the system optimizes the balance between reducing refitting time and maintaining variant manufacturing capability without arbitrary assignments.
Data Source
AI summary
A method for populating circuit boards by equipment on a populating line. The method includes acts of providing the equipment comprising a number of component types sufficient to populate a setup family of circuit board types assigned to the equipment, acquiring a number of the circuit board types with assigned circuit boards configured to be populated on the populating line within the planning horizon, assigning the circuit board types to the fixed equipment setup family, determining an assignment quality from a number of orders during a planning interval, optimizing the assignment of the circuit board types to the fixed equipment setup family by a mixed integer programming until the assignment quality exceeds a predetermined amount, and populating the circuit boards on the populating line with the components from the plurality of shuttle tables by at least one populating robot.