Component Mounting Line Balance Evaluation Using Machine Exclusion
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Solution Overview
Problem
In component mounting lines where specific component types are allocated to certain machines, the line balance efficiency worsens due to limited mounting points, making it difficult to evaluate optimization results and utilize the original device performance, as processing conditions are often set to default values without ensuring optimal settings.
Innovation Solution
An optimization device that calculates and displays the effectiveness degree of processing conditions, allowing operators to adjust and optimize settings for improved line balance efficiency and device performance by excluding machines with specific component types and calculating line balance efficiency based on optimized cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If component mounting machines with specific component type allocation (tray devices, abnormal shape suction nozzles) are included in the line balance efficiency calculation, then the evaluation reflects the actual production capacity, but the line balance efficiency worsens due to limited mounting points
Solution Approach 1:
The patent segments the component mounting machines into two categories: those with specific component type allocation (tray devices, abnormal shape suction nozzles) and those without. The line balance efficiency calculation is performed separately for each segment, allowing accurate evaluation of machines with specialized functions while maintaining overall productivity assessment.
Solution Approach 2:
Machines with specific component type allocation are extracted from the general line balance efficiency calculation. These machines are evaluated separately to prevent their limited mounting points from artificially reducing the overall efficiency metric, while still being included in the comprehensive production capacity evaluation.
2Reliability
If processing conditions are set to default values to ensure safe operation, then operational reliability is maintained, but optimization results cannot be properly evaluated and original device performance is not utilized
Solution Approach 1:
The system performs preliminary optimization calculations using default processing conditions to establish a baseline performance level. This preliminary action allows safe operation while providing a reference point for evaluating the potential improvements from optimized settings, enabling operators to make informed decisions about adjusting processing conditions.
Solution Approach 2:
The patent implements a feedback mechanism that compares actual production results with optimized target values. This feedback loop allows operators to evaluate whether default settings are adequate or if optimization is needed, while maintaining operational reliability through continuous monitoring and gradual adjustment of processing conditions.
3Productivity
If optimization process is performed with limited time to meet production schedules, then productivity is maintained, but excellent optimization results may be missed and original device performance cannot be fully utilized
Solution Approach 1:
The system performs a partial optimization process within the limited time available, focusing on the most critical processing conditions that have the greatest impact on line balance efficiency. This partial action approach ensures that optimization is completed within production schedules while still achieving meaningful improvements by concentrating resources on high-impact parameters.
Data Source
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AI summary
An optimization device (7) of a component mounting line (1) of the present invention includes a cycle time calculating section (831) which calculates respective cycle times (tc) required for mounting components of component types which are allocated to each of the component mounting machines (21 to 2A) by the optimization process onto a single board (K), an excluded machine setting section (832) which sets a specific portion of the component mounting machines (2A) to be excluded from further calculation processes, a balance efficiency calculating section (833) which calculates a line balance efficiency (LBE) indicating a degree to which the cycle times of the component mounting machines (21 to 29) which are not excluded are equalized, and a balance efficiency display section (834) which displays the line balance efficiency. Accordingly, the results of the optimization process which is carried out before starting production of the board are evaluated appropriately and the original device performance of the component mounting line can be utilized.