Electronic Component Mounting System Equipment Unit Allocation
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Solution Overview
Problem
Existing electronic component mounting systems face reduced productivity due to improper management of equipment units, leading to unnecessary machine suspensions and decreased operation rates when equipment units reach predetermined usage limits, causing errors and inefficiencies.
Innovation Solution
An electronic component mounting system with a unit management method that includes storage sections for manufacturing plans, unit management data, and inventory data, allowing for the allocation and reservation of equipment units based on their use permission status, ensuring only usable units are allocated to manufacturing lots, thereby preventing machine suspensions and optimizing equipment usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If equipment units are managed by counting operation times and issuing warnings when reaching preset limits, then equipment deterioration can be detected, but machine operation rate decreases due to unnecessary suspensions
Solution Approach 1:
The system performs preliminary allocation of equipment units to manufacturing lots before actual production begins. By determining equipment availability and allocating resources in advance, the system avoids mid-operation suspensions and ensures continuous production while maintaining equipment deterioration monitoring
Solution Approach 2:
The equipment unit management system dynamically adjusts allocation based on real-time status. Equipment units that have not reached their operation limits can be reallocated to new manufacturing lots, creating a flexible system that adapts to changing production requirements while maintaining reliability
2Productivity
If equipment units are continuously used without replacement, then productivity is maintained, but equipment deterioration increases leading to errors
Solution Approach 1:
The system implements feedback mechanisms by continuously monitoring equipment unit operation counts and comparing them against preset limits. This feedback loop enables the system to identify when equipment units need replacement, allowing proactive maintenance that prevents errors while minimizing disruption to continuous production
3Reliability
If equipment units are replaced frequently to maintain functionality, then reliability is improved, but productivity decreases due to replacement operations
Solution Approach 1:
The system performs preliminary allocation of equipment units to manufacturing lots before production begins. By planning equipment usage in advance and allocating units that are guaranteed to be functional for the required duration, the system eliminates the need for frequent replacements during operation, maintaining both reliability and productivity
Data Source
AI summary
An electronic component mounting system stores: manufacturing plan data for each manufacturing lot; unit management data including use permission information indicating a use permission status of an equipment unit; and inventory data indicating a stock status of the equipment units. In a unit reservation processing, new allocation processing is performed for allocating an equipment unit necessary for manufacture of a new manufacturing lot to an equipment unit for a new manufacturing lot, and an allocation result is registered. The system determines whether an equipment unit of an allocation subject in the new allocation processing can be allocated to an equipment unit for the new manufacturing lot by referring to use permission information of the equipment unit, and if the equipment unit is determined as being usable, the unit reservation processing is performed.