Setup Family Optimization for Printed Circuit Board Assembly Lines
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Solution Overview
Problem
Existing methods for determining setup families on assembly lines for printed circuit board production are often manual, inefficient, or tied to specific pick and place systems, leading to frequent setup changes and high storage device requirements, resulting in increased costs and production downtimes.
Innovation Solution
A method using integral linear programming to create and optimize setup families by distributing printed circuit boards among existing families based on component types, reducing the number of setup families and minimizing component type changes, thereby reducing production downtimes and storage needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual methods or existing tools are used to determine setup families, then the process can be performed, but it requires manual effort and does not deliver convincing results
Solution Approach 1:
The patent replaces manual mechanical determination methods with an automated computer-based system that uses mathematical optimization algorithms (integer linear programming) to automatically determine optimal setup families, eliminating manual effort while ensuring mathematically optimal and reliable results
Solution Approach 2:
The patent transforms the setup family determination problem into a mathematical optimization problem by defining objective functions and constraints based on production data, component types, and setup times, allowing automated computation of optimal groupings through parameter optimization
2Adaptability or versatility
If the number of setup families is increased to reduce component type changes, then setup flexibility improves, but production downtime increases due to frequent retrofitting
Solution Approach 1:
The patent performs preliminary determination of optimal setup families using integer linear programming before actual production, pre-optimizing the groupings to minimize future setup changes and associated downtimes while maintaining flexibility for different production scenarios
Solution Approach 2:
The system uses production data, component type information, and setup family performance metrics as feedback to continuously refine and optimize setup family assignments, adjusting groupings to balance flexibility needs with downtime reduction goals
3Adaptability or versatility
If more storage devices are kept ready for further setup families, then setup change capability improves, but costs increase
Solution Approach 1:
The patent merges the determination of setup families with the optimization of storage device utilization, using integer linear programming to simultaneously minimize the number of storage devices required while maintaining adequate setup change capability through optimal family groupings
Solution Approach 2:
The patent creates universal setup families that can serve multiple production scenarios and component type combinations, allowing a smaller number of storage devices to handle a wider variety of setup requirements through carefully optimized family assignments
Data Source
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AI summary
The invention concerns a fitting line which is arranged to fit printed circuit boards with electronic components. A method for determining equipment families for the fitting line comprises the following steps: initial forming of a number of equipment families, each having allocated printed circuit boards; selecting of one of the equipment families; and distributing of the printed circuit boards of the selected equipment family to the other equipment families by means of integral linear programming.