Component Mounter Setup List Editing for Schedule Changes
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Solution Overview
Problem
The existing setup support devices for component mounters are inefficient in adapting to changes in production schedules, leading to increased production time and reduced operating rates when production schedules are altered, such as when unplanned board products need to be produced or scheduled products are canceled.
Innovation Solution
A setup support device that includes a memory section for storing production schedules, a list editing section to dynamically adjust the setup list in response to operator requests or schedule changes, and a guidance section to prioritize and optimize the setup process, ensuring efficient use of resources and minimizing unnecessary setups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the setup list is generated in advance by optimization processing, then the efficiency of work is improved, but the production time increases when the production schedule is changed
Solution Approach 1:
The setup support device dynamically updates the setup list based on changes in the production schedule. When the production schedule is modified, the device automatically regenerates the setup list reflecting the new schedule, allowing the system to adapt to changes without manual intervention and avoiding the time loss associated with static, pre-generated setup lists.
Solution Approach 2:
The device implements a feedback mechanism where changes in the production schedule are detected and trigger automatic updates to the setup list. The system continuously monitors the production schedule and adjusts the setup list accordingly, ensuring that the setup information remains current and relevant to the actual production requirements.
2Ease of operation
If all scheduled setups are completed in advance, then the setup list is ready, but the operation rate of the component mounter decreases when the starting time of the next production job is approaching
Solution Approach 1:
The device performs preliminary actions by preparing the setup list in advance based on the production schedule, but only includes setups that are actually needed by their respective start times. This allows the system to have setup information ready without forcing unnecessary setups to be completed before they are needed, thus maintaining high operating rates.
Solution Approach 2:
The setup list is dynamically adjusted based on time parameters, specifically the start time of production jobs. The device modifies the setup list to include only those setups that are necessary before their corresponding production jobs begin, optimizing the balance between setup readiness and maintaining high operating rates during production.
3Adaptability or versatility
If the setup list is regenerated when the production schedule changes, then the setup information is updated, but the production time increases
Solution Approach 1:
The setup support device performs self-service by automatically detecting changes in the production schedule and regenerating the setup list without requiring manual intervention. This automation eliminates the time loss that would otherwise be incurred through manual setup list updates, allowing the system to adapt to schedule changes efficiently and maintain current setup information.
4Ease of operation
If the operator performs setup according to the printed setup list, then the setup process is guided, but the flexibility to handle schedule changes is reduced
Solution Approach 1:
The device replaces the static mechanical system of printed setup lists with a dynamic electronic display system. The setup list is displayed on a screen and can be automatically updated when the production schedule changes, providing both guidance to the operator and the flexibility to adapt to schedule changes without requiring physical reprinting or manual updates.
Data Source
AI summary
A setup support device capable of editing a setup list in accordance with a change in a production schedule or the like, thereby enabling more efficient setup of a component mounter. The setup support device includes a list editing section for performing editing to increase or decrease production jobs included in a setup list in accordance with a request from an operator who performs setup at the component mounter or a change in a production schedule, and a guidance section for issuing setup guidance for the production jobs to the operator based on the edited setup list.