Feeder Management for Setup Change Efficiency
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Solution Overview
Problem
The existing feeder management methods are inefficient in determining whether to remove a reel during setup changing work, especially in multi-type small-volume production, as they lack clear guidance on reel exchange and feeder slot management, leading to increased workload and errors.
Innovation Solution
A feeder management method and device that automatically compare current and required component types based on production plans, guiding the removal or maintenance of reels and feeders to optimize setup changing work, reducing operator effort and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual verification of component types is performed during setup changing work, then accuracy of reel removal determination is improved, but operator workload and time consumption increase
Solution Approach 1:
The system performs self-verification by automatically comparing current component types with required component types from the production plan, eliminating the need for manual operator verification. The control device autonomously determines which reels should be removed and provides guidance to operators.
Solution Approach 2:
Manual verification processes are replaced with an automated information processing system that uses the production plan and component type data to automatically determine reel removal decisions, substituting human cognitive work with computational logic.
2Productivity
If comprehensive feeder management guidance is implemented, then setup changing efficiency is improved, but system complexity increases
Solution Approach 1:
The control device leverages the existing production plan management functionality to perform multiple tasks: it not only manages production scheduling but also automatically determines reel removal decisions and provides feeder management guidance, making the existing system perform multiple functions without adding dedicated hardware.
Solution Approach 2:
The system uses the production plan as an intermediary information source to bridge the gap between current feeder states and required component types, enabling automated decision-making without requiring direct complex sensing or verification mechanisms.
3Measurement precision
If automatic comparison of component types is implemented, then determination accuracy is improved, but information processing requirements increase
Solution Approach 1:
The system performs preliminary actions by maintaining the production plan with all required component type information in advance. This pre-organized information structure enables efficient comparison and decision-making during setup changing without requiring complex real-time data processing.
Data Source
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AI summary
The present invention provides a feeder management method for managing feeders when producing a board based on a production plan using: a board conveyance device; a component supply device in which multiple feeders are detachably mounted at multiple installation positions; and an electronic component mounter including a component transfer device; wherein a feeder management method configured to manage a feeder when producing a board based on a production plan specifying a production order of multiple types of boards in a predetermined future period by using: a board conveyance device; a component supply device in which multiple feeders are detachably mounted at multiple predetermined positions, and an electronic component mounter including a component transfer device, wherein the feeder management method comprises: a current state memory step of linking and storing a current component type of the electronic components, being supplied by the currently mounted feeder, and a position of the mounted feeder; a plan memory step of linking and storing required component types of the electronic components, being mounted on the multiple types of boards, and a position of the feeder of supplying the required components, and a reel removal guide step of guiding to remove a first reel from a first feeder of supplying the electronic components of which current state component type does not match any of the required component types. With this, the first reel is removed from the first feeder which supplies the electronic component of the current component type which is not scheduled to be used, enabling the operator to remove the first reel without difficulty in setup changing work, and work efficiency is improved.