Production Line Conveyance Control for Maintenance Buffer Reduction
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Solution Overview
Problem
In manufacturing lines for board products, maintenance errors can lead to prolonged production halts, causing circuit boards to deteriorate and increasing removals, especially when multiple boards are held in buffer devices upstream from the maintenance target device.
Innovation Solution
A manufacturing management device that determines the necessity of maintenance and stops loading circuit boards onto a reference device positioned upstream from the maintenance target device, reducing the number of boards held between the reference device and the maintenance target device, thereby minimizing removals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the production line continues loading circuit boards during maintenance, then productivity is maintained, but the number of removed circuit boards increases due to quality deterioration
Solution Approach 1:
The control unit predicts maintenance timing in advance and stops loading circuit boards onto the reference device before maintenance is actually needed. This preliminary action prevents circuit boards from being held in the buffer device for extended periods, thereby reducing quality deterioration and the number of removed boards while maintaining production efficiency
2Adaptability or versatility
If circuit boards are held in the buffer device for extended periods, then production flexibility is improved, but circuit board quality deteriorates
Solution Approach 1:
The control unit continuously monitors the number of circuit boards held in the buffer device and adjusts the loading stop timing based on this feedback. By predicting maintenance timing and comparing it with the current buffer status, the system dynamically controls when to stop loading, thereby maintaining production flexibility while preventing quality deterioration
Data Source
AI summary
A manufacturing management device includes a determination section configured to determine the necessity of maintenance on any of the multiple production devices during production by the production line; and a conveyance management section configured to stop loading circuit boards, at a predetermined time, onto a reference device among the multiple production devices when it is determined that maintenance is necessary, the reference device being positioned upstream in the production line from a maintenance target device having a cause for maintenance.