Facility Configuration Creator for Component Mounting Line Cost Reduction
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Solution Overview
Problem
Existing facility configuration creation systems for component mounting lines lack clarity on whether changing the configuration actually reduces costs, as they focus on optimizing productivity and investment cost without ensuring actual cost reduction.
Innovation Solution
A facility configuration creation support system and method that includes a facility configuration creator and management storage to calculate and compare total costs before and after configuration changes, ensuring a new configuration reduces overall costs by predicting production time, facility availability, worker numbers, and change costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If facility configuration is changed to optimize productivity and investment cost, then productivity and facility investment cost are improved, but it is unclear whether total cost is actually reduced
Solution Approach 1:
The system calculates and compares total costs before and after facility configuration changes, providing feedback on whether the change actually reduces costs. This feedback mechanism resolves the uncertainty about cost reduction by presenting clear comparative data between current and proposed configurations.
Solution Approach 2:
The facility configuration creator acts as an intermediary that objectively calculates and compares total costs, bridging the gap between configuration changes and cost assessment. This intermediary provides clear information about whether costs are reduced, eliminating the uncertainty.
2Quantity of substance
If facility configuration is changed to optimize investment cost, then facility investment cost is reduced, but actual total cost reduction is not ensured
Solution Approach 1:
The system provides feedback by calculating total costs including operation costs and comparing them before and after facility configuration changes. This ensures that investment cost reductions are validated against actual total cost impacts, providing reliability in cost reduction decisions.
Solution Approach 2:
The system performs preliminary calculation of total costs for proposed facility configurations before implementation. By calculating operation costs and total costs in advance, the system ensures that configuration changes will actually reduce total costs, not just investment costs.
3Stability of the object's composition
If current facility configuration is continued, then existing costs are maintained, but cost reduction opportunities are missed
Solution Approach 1:
The system performs preliminary analysis and calculation of alternative facility configurations before committing to the current configuration. By evaluating multiple options and calculating their total costs in advance, the system identifies cost reduction opportunities that would otherwise be missed by simply continuing the current configuration.
Solution Approach 2:
The system provides feedback on potential cost reductions by comparing alternative configurations against the current configuration. This feedback mechanism reveals cost reduction opportunities by showing the difference between maintaining status quo and implementing optimized configurations.
Data Source
AI summary
A facility configuration creation support method which supports creation of a facility configuration of a component mounting line which includes a component mounter includes a facility configuration creation step of creating a new facility configuration in which a total cost is reduced as compared to a current total cost in continuing production with a current facility configuration when producing in a specific period in the component mounting line.