Component Replenishment Sequencing for Multi-Line Mounting Devices
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Solution Overview
Problem
Existing component management systems fail to efficiently assign component replacement tasks to workers, leading to potential facility stops due to component shortages, as timely and accurate information about component shortages is not always provided across multiple component mounting lines.
Innovation Solution
A management apparatus and method that acquires remaining component information from each mounting device, generates work sequences for workers based on their working ranges and component availability, and transmits these sequences to ensure timely component supply, thereby preventing facility stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If component replacement work is simply assigned to a worker who is suitable for the work, then the assignment process is straightforward, but information about component shortage is not given timely and surely, leading to facility stop
Solution Approach 1:
The management apparatus establishes a feedback mechanism where component mounting devices continuously report component remaining numbers to the management apparatus, which then generates and transmits work sequence information to workers. This closed-loop feedback system ensures timely and accurate information delivery about component shortages, resolving the reliability issue while maintaining operational simplicity.
Solution Approach 2:
The management apparatus acts as an intermediary between component mounting devices and workers. It collects component remaining number information from devices, processes this information, and generates appropriate work sequence instructions for workers. This intermediary role ensures reliable information transmission without complicating the direct worker-device interaction.
2Reliability
If workers are distributed to multiple component mounting lines to monitor component levels, then component shortages can be detected, but the work load and complexity of management increases
Solution Approach 1:
Component mounting devices automatically monitor their own component remaining numbers and report this information to the management apparatus without requiring worker intervention. This self-service capability eliminates the need for workers to physically check component levels, reducing work load and management complexity while maintaining reliable detection.
Solution Approach 2:
The patent replaces the mechanical system of workers physically monitoring component levels with an automated information system. The management apparatus electronically collects, processes, and distributes component status information, substituting human labor with automated digital communication and reducing overall system complexity.
3Reliability
If component remaining number information is continuously monitored and work sequences are generated for multiple workers across multiple lines, then facility stop due to component shortage is suppressed, but the complexity of the management apparatus increases
Solution Approach 1:
The management apparatus processes information for multiple component mounting lines by dividing it into separate work sequence sets, one for each worker or line. This segmentation allows the system to handle multiple lines independently and systematically, managing complexity through structured division of information processing tasks.
Solution Approach 2:
The management apparatus generates work sequence information in advance based on predicted component usage and remaining numbers. By preparing work sequences before component shortages actually occur, the system proactively prevents facility stops while maintaining manageable complexity through advance planning and information processing.
Data Source
AI summary
A management apparatus manages works to supply components to component mounting devices in a component mounting line. The management apparatus includes a component remaining number information acquisition portion that acquires, from each of the component mounting devices, a remaining number of components stored in the component mounting device, a worker information storage portion that stores worker information including a working range of each of workers in the component mounting line, a work sequence decision portion that generates work sequence information indicating a work sequence of component supply works for each of the workers based on the worker information and component remaining number information about a plurality of components within a predetermined period of time, and an information transmission portion that transmits the work sequence information to the workers who should perform the works.