Dynamic Mounting Order for Component Shortage Management
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Solution Overview
Problem
Existing mounting machine optimization methods do not account for component shortages during the mounting process, leading to increased process time due to suspended operations when a component runs out.
Innovation Solution
The mounting machine prioritizes the mounting of components with a higher likelihood of running out earlier in the sequence, allowing for parallel processing of other components when a shortage occurs, and adjusts the mounting order to ensure that replenishment and continued processing can happen efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mounting machine follows the optimized mounting order that minimizes head movement distance, then the mounting efficiency is improved, but the mounting time increases when a component runs out because the process must be suspended for replenishment
Solution Approach 1:
The mounting machine performs preliminary actions by mounting components that are less likely to run out before components that are more likely to run out. The control unit calculates the probability of each component running out based on remaining quantity and required quantity, and adjusts the mounting order dynamically to ensure components with higher depletion risk are addressed first, allowing parallel replenishment operations without halting the entire process
Solution Approach 2:
The mounting order is made dynamic rather than static. The control unit continuously monitors component quantities and recalculates the optimal mounting sequence in real-time based on current stock levels and requirements. This dynamic adjustment allows the system to adapt to changing component availability and minimize interruptions by proactively addressing components that are running low
2Length of moving object
If the mounting machine processes components in the original optimized order without considering component availability, then the head movement distance is minimized, but the process suspension time increases when a component depletes
Solution Approach 1:
The system changes the parameter of mounting order based on component depletion probability. Instead of following a fixed optimized sequence, the control unit dynamically adjusts the sequence by calculating for each component: (remaining quantity) / (required quantity) to determine depletion risk. Components with higher depletion probability are prioritized in the mounting sequence, transforming the static optimized order into a dynamic adaptive order that minimizes process suspensions
Data Source
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AI summary
A mounting machine determines whether or not there is an occurrence of running out of a component in a mounting process based on initial order information 86 and the number of remaining components, and when the mounting machine determines that there is running out of a component, a modified order that is indicated by modified order information 86a in which the determined component is preferentially mounted is set as the mounting order. In addition, in the mounting machine, during the mounting process when components of a subsequent mounting target run out in the mounting order, and the components later in the mounting order than these components do not run out, the component that does not run out is mounted previously on the board. Furthermore, the initial order which is indicated by the initial order information 86 is set in advance as an order such that a component (component A) in the plurality of components that has a higher frequency of occurrence of running out than another component is preferentially mounted.