Feeder Arrangement Planning for Jump-the-Queue PCB Jobs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
During production of component-mounted boards, unscheduled jump-the-queue jobs often require different feeder arrangements, leading to manual changeover work that decreases productivity, as the feeder arrangement for the current setup group needs to be changed to accommodate the jump-the-queue job and then returned.
Innovation Solution
A production plan creation system that groups production jobs into setup groups to include predicted or entered jump-the-queue jobs, allowing these jobs to be performed without changeover by optimizing feeder arrangements based on priority and frequency, ensuring the jump-the-queue job can be executed within existing setup groups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If feeders are arranged according to the current setup group configuration, then production of the current setup group can proceed efficiently, but jump-the-queue jobs requiring different feeder arrangements cannot be performed without manual changeover
Solution Approach 1:
The system performs preliminary action by predicting jump-the-queue jobs in advance and pre-including them in multiple setup groups during production plan creation. This allows the feeder arrangement to be prepared beforehand to accommodate both the current setup group and predicted jump-the-queue jobs, eliminating the need for manual changeover when jump-the-queue jobs occur.
Solution Approach 2:
The system applies universality by creating setup groups that can serve multiple purposes - they are configured to handle both the original production jobs and predicted jump-the-queue jobs. By including jump-the-queue jobs in multiple setup groups, the same feeder arrangement can accommodate different job types without requiring manual reconfiguration.
2Adaptability or versatility
If manual changeover is performed to accommodate jump-the-queue jobs, then the jump-the-queue job can be executed, but productivity decreases due to additional manual operations
Solution Approach 1:
The system predicts jump-the-queue jobs in advance during production plan creation and pre-configures setup groups to include these jobs. This preliminary action eliminates the need for manual changeover operations when jump-the-queue jobs occur, maintaining high productivity while still accommodating unscheduled jobs.
3Productivity
If feeders are arranged to accommodate all components for multiple consecutive production jobs, then changeover operations are reduced, but the system cannot adapt to unscheduled jump-the-queue jobs with different component requirements
Solution Approach 1:
The system performs preliminary prediction of jump-the-queue jobs and pre-includes them in multiple setup groups during production plan creation. This allows the feeder arrangement to be optimized for multiple jobs including unscheduled ones, achieving both reduced changeover operations and adaptability to new job requirements.
Solution Approach 2:
The system uses feedback from predicted jump-the-queue job information to adjust and optimize feeder arrangements in setup groups. By incorporating prediction results into the production plan, the system continuously improves its ability to handle both scheduled and unscheduled jobs efficiently.
Data Source
AI summary
A production plan creation computer, in a production plan creation process before starting production, creates or enters multiple production jobs required for producing the multiple types of component-mounted boards that are planned to be produced, and predicts or enters a production job that may become a jump-the-queue job to be produced unscheduled while one of the multiple production jobs is being produced. Next, the jump-the-queue job and the production jobs are grouped into multiple setup groups, with the jump-the-queue job being included in all the setup groups. Here, the jobs are grouped in each setup group such that it is possible to switch between the production jobs and the jump-the-queue job without performing changeover. The priorities of the jump-the-queue job and the production jobs are determined, and the feeder arrangement is optimized for each setup group based on the priorities of the jump-the-queue job and the production jobs.