Component Mounter Count Planning for Real-World Line Balance
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Solution Overview
Problem
In production lines, the cycle time variations across devices lead to line balance deterioration, and existing optimization devices fail to account for periodic operations and error handling times, resulting in inefficiencies and delays.
Innovation Solution
An optimization device that sets target times considering periodic operation times and error handling times, calculating the optimal number of component mounters to balance production line capacity and reduce bottlenecks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the unit number of component mounters is designed to even out cycle times in theoretical design, then the line balance is optimized in ideal conditions, but the line balance deteriorates in actual production due to unaccounted periodic operations and error handling times
Solution Approach 1:
The patent applies preliminary action by pre-calculating and incorporating the time required for periodic operations (such as maintenance, material replacement) and error handling into the cycle time design phase. The optimization device computes adjusted cycle times that include these necessary interruptions before actual production begins, ensuring that the line balance accounts for real-world operational disruptions rather than ideal conditions only.
Solution Approach 2:
The patent changes the parameters used in cycle time calculation by introducing additional time components for periodic operations and error handling. Instead of using only the base processing time, the optimization device modifies the cycle time parameter to include buffers for maintenance activities and error corrections, thereby creating a more realistic and stable line balance that adapts to actual production conditions.
2Reliability
If periodic operations (maintenance, material replacement) are executed in production devices, then device reliability is maintained, but conveyance of circuit boards is delayed and line balance deteriorates
Solution Approach 1:
The optimization device performs preliminary calculation of periodic operation times and incorporates them into the cycle time design. By planning maintenance and material replacement activities in advance within the cycle time framework, the system minimizes unexpected conveyance delays and maintains smoother production flow while ensuring device reliability through scheduled operations.
Solution Approach 2:
The patent aims to maintain continuity of useful action by integrating periodic operations into the overall cycle time calculation rather than treating them as separate interruptions. The optimization device schedules maintenance and material replacement activities in a way that minimizes disruption to the continuous flow of circuit boards, ensuring that useful production action continues with minimal interruption.
3Manufacturing precision
If error handling is executed for mounting errors, then production quality is maintained, but the required time of production process increases and cycle time is extended
Solution Approach 1:
The optimization device changes the cycle time parameter by adding error handling time to the base processing time. This modified cycle time parameter reflects the actual time required to complete mounting operations including error corrections, allowing for more accurate line balance calculations that account for quality maintenance activities without extending the overall production timeline unexpectedly.
Solution Approach 2:
The patent applies beforehand cushioning by incorporating error handling time into the cycle time design before actual production begins. This creates a time buffer that accommodates expected error corrections without causing delays to the production schedule, thereby maintaining manufacturing precision while preventing production process time extensions.
4Productivity
If the cycle time is set based on maximum time of production devices excluding periodic operations, then the bottleneck process is identified, but excess and deficiency of process capacity occur when periodic operations are executed
Solution Approach 1:
The optimization device changes the target time parameter by incorporating periodic operation times into the cycle time calculation. This adjusted parameter provides a more accurate basis for determining the number of component mounters needed, ensuring that process capacity is properly balanced to handle both production requirements and maintenance activities without creating excess or deficiency conditions.
Data Source
AI summary
An optimization device is applied to a production line in which multiple production devices respectively execute a production process. The optimization device includes a cycle time setting section configured to set a cycle time for each production device, a target time setting section configured to set a target time based on a cycle time and a time required for periodic operation in each of multiple production devices except for the component mounter, and a line design section configured to calculate the unit number of the component mounters constituting the production line based on the target time.