Component Mounter Changeover Configuration for Shorter Operator Paths
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Solution Overview
Problem
Conventional optimization techniques for component mounting lines focus on improving mounting operation efficiency without considering the workability of changeover operations, leading to inefficient changeover processes, particularly in high-mix low-volume production, where frequent type switches occur and operator movements can be lengthy or interfere with each other.
Innovation Solution
A changeover operation configuration device and method that register line layout, work area, and personnel information to select and aggregate component types efficiently, set component supply device targets, and optimize their positions to minimize operator movement and interference, thereby enhancing changeover efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional optimization techniques are used to improve mounting operation efficiency, then mounting operation efficiency is improved, but changeover operation efficiency deteriorates
Solution Approach 1:
The patent segments the changeover operation configuration into distinct phases: component type aggregation, component supply device selection, and arrangement position determination. This segmentation allows independent optimization of each phase, enabling the system to improve mounting efficiency through optimized component arrangement while separately optimizing changeover efficiency through strategic device selection and positioning, thus resolving the contradiction between the two operational efficiencies
Solution Approach 2:
The patent performs preliminary actions by pre-aggregating component types and pre-selecting component supply devices before the actual changeover operation. By determining the arrangement positions of component supply devices in advance based on predicted changeover requirements, the system prepares optimal configurations beforehand, reducing the time and complexity of actual changeover operations while maintaining efficient mounting operations
2Productivity
If component supply devices are arranged to optimize mounting operations, then mounting efficiency is improved, but operator movement path length increases
Solution Approach 1:
The patent applies local quality by optimizing the arrangement positions of component supply devices based on their specific roles and the local requirements of different mounting positions. Instead of uniform arrangement, the system determines specific arrangement positions for each component supply device according to the aggregated component types and mounting line configuration, creating locally optimized arrangements that reduce operator movement paths while maintaining overall mounting efficiency
3Adaptability or versatility
If multiple component supply devices are used as work targets, then component type coverage is improved, but operator interference increases
Solution Approach 1:
The patent applies partial action by selecting a restricted number of component supply devices as work targets from the total available devices. The aggregation section identifies only the necessary component types for changeover and selects minimal required component supply devices as work targets, rather than involving all devices. This partial involvement reduces operator interference while still achieving comprehensive component type coverage through strategic selection
Data Source
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AI summary
A changeover operation configuration device for use in a component mounting line configured from multiple component mounters lined up in a row, the component mounters each having a component supply device configured to supply multiple component types of electronic components and being configured to mount the electronic components on a board, the changeover operation configuration device being configured to set in advance changeover work of switching the multiple component types when a board type of the board is switched, the changeover operation configuration device including: a registration section configured to register information of at least one of line layout information related to an arrangement of the component mounting line, work area layout information related to an arrangement of a work area at which the changeover operation is to be performed, and personnel quantity information of a quantity of operators who are to perform the changeover operation; an aggregation section configured to select the component type for which to perform changeover operation from the multiple component types, aggregate the component types to a restricted quantity of the component supply devices and designate the component supply devices as work targets; and a setting section configured to set an arrangement position of the component supply devices that are the work targets based on the at least one of the registered information.