Component Replenishment Scheduling With Overlapping Time Windows
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing work plan management systems for component mounting processes impose a significant burden on workers due to individually timed component replenishment tasks, requiring frequent and urgent movements between mounters, and also include ancillary work that adds to the workload.
Innovation Solution
A work plan management system that includes a component replenishment management unit to monitor supply status and specify overlapping replenishment time windows for batch replenishment, and an ancillary work management unit to coordinate ancillary tasks within these windows, allowing for coordinated and efficient setup work planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If component replenishment work is scheduled individually for each component supply device, then component supply continuity is maintained, but worker burden increases due to frequent movements between mounters
Solution Approach 1:
The patent combines multiple individual component replenishment tasks into a single batch replenishment operation by identifying overlapping time windows where multiple component supply devices can be replenished simultaneously. This merging approach maintains component supply continuity while reducing the frequency of worker movements between mounters.
Solution Approach 2:
The system performs preliminary analysis to predict component shortage timing and calculate overlapping replenishment time windows in advance. By planning batch replenishment operations beforehand, the system enables workers to prepare and execute replenishment tasks more efficiently, reducing urgent movements between mounters.
2Reliability
If multiple ancillary work tasks are performed in addition to component replenishment, then production maintenance is ensured, but overall setup work burden increases
Solution Approach 1:
The patent integrates multiple ancillary work tasks (such as suction nozzle cleaning and backup pin replacement) with component replenishment work into a coordinated batch operation. By merging these tasks and scheduling them within the same overlapping time windows, the system ensures production maintenance while reducing the overall complexity and burden of setup work.
Solution Approach 2:
The work plan management system performs multiple functions simultaneously: it manages component replenishment, schedules ancillary work tasks, predicts shortages, and coordinates worker assignments. This multi-functionality allows the system to handle diverse maintenance requirements through a unified approach, reducing overall setup work complexity.
3Reliability
If workers hurry from mounter to mounter for individual replenishment tasks, then component supply devices are replenished timely, but production efficiency decreases
Solution Approach 1:
The system calculates overlapping replenishment time windows in advance and provides this information to workers before they need to perform replenishment tasks. This preliminary planning allows workers to move methodically between mounters rather than hurrying, maintaining timely replenishment while improving production efficiency.
Solution Approach 2:
The work plan management system automatically generates optimized replenishment schedules and provides them to workers, enabling them to work independently without constant supervision or coordination. This self-service approach ensures timely replenishment while allowing workers to maintain a steady, efficient pace without hurrying between tasks.
Data Source
AI summary
This work plan management system is provided with a component replenishment management unit for managing a plan for component replenishment work to be performed on component supply devices; and an ancillary work management unit for managing a plan for ancillary work. The component replenishment management unit includes a component supply monitoring unit and a replenishment target specifying unit. The component supply monitoring unit specifies, for each of the component supply devices, replenishment possibility time windows during which component replenishment work is possible. The replenishment target specifying unit recognizes overlapping replenishment time windows in which the individual replenishment possibility time windows overlap, and specifies component supply devices on which it is possible to perform component replenishment work during the overlapping replenishment time windows. The ancillary work management unit specifies ancillary work that is to be started during the overlapping replenishment time windows.