Component Mounting Line Cycle Balancing with Machine Exclusion
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Solution Overview
Problem
In component mounting lines where specific component types are allocated to certain machines, the line balance efficiency worsens due to limited mounting points and fixed allocation, making it difficult to optimize processing conditions and evaluate optimization results effectively.
Innovation Solution
An optimization device that calculates and displays operation efficiencies for each machine, allowing operators to adjust settings and exclude machines with abnormal allocations, ensuring optimal processing conditions and evaluating optimization results accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If specific component types are allocated to certain component mounting machines with fixed structures (tray devices, abnormal shape suction nozzles), then those machines can process specialized components, but the line balance efficiency worsens due to limited mounting points and fixed allocation
Solution Approach 1:
The patent segments the component mounting line into two categories: machines with fixed special structures (tray devices, abnormal shape suction nozzles) that process specific component types, and general-purpose machines that can be freely allocated. This segmentation allows the optimization device to separately evaluate and optimize each group, preventing fixed-structure machines from negatively impacting the overall line balance efficiency calculation while maintaining their specialized functionality.
2Productivity
If optimization process is performed including all component mounting machines, then comprehensive optimization is achieved, but evaluation of optimization results becomes difficult when some machines have fixed allocations
Solution Approach 1:
The patent extracts machines with fixed special structures from the general optimization evaluation process. The optimization device identifies these machines based on their structural characteristics (tray devices, abnormal shape suction nozzles) and excludes them from the line balance efficiency calculation. This extraction allows accurate evaluation of optimization results for freely allocatable machines while maintaining separate tracking of fixed-structure machine allocations.
3Productivity
If component mounting machines with fixed allocations are included in line balance efficiency calculation, then complete line performance is measured, but the evaluation becomes inaccurate due to unavoidable cycle time differences
Solution Approach 1:
The patent applies different evaluation criteria to different groups of machines. For machines with fixed special structures, the system recognizes that their cycle times inherently differ due to structural constraints, so it applies a local exemption from the standard line balance efficiency calculation. For general-purpose machines, the standard optimization evaluation applies. This local quality approach ensures accurate measurement where applicable while acknowledging structural limitations where they exist.
Data Source
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AI summary
An optimization device (7) of a component mounting line (1) of the present invention includes a cycle time calculating section (831) which calculates respective cycle times (tc) required for mounting components of component types which are allocated to each of the component mounting machines (21 to 2A) by the optimization process onto a single board (K), an excluded machine setting section (832) which sets a specific portion of the component mounting machines (2A) to be excluded from further calculation processes, a balance efficiency calculating section (833) which calculates a line balance efficiency (LBE) indicating a degree to which the cycle times of the component mounting machines (21 to 29) which are not excluded are equalized, and a balance efficiency display section (834) which displays the line balance efficiency. Accordingly, the results of the optimization process which is carried out before starting production of the board are evaluated appropriately and the original device performance of the component mounting line can be utilized.