Pick-and-Place Line Scheduling for Faster PCB Setup Changes
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Solution Overview
Problem
The existing pick-and-place line production processes face inefficiencies due to lengthy setup times and downtimes, leading to reduced throughput, as changing tables need to be completely set up and refitted, which can take hours and result in production delays and reduced line utilization.
Innovation Solution
A method and control device that optimize the sequence of clusters and changing table sets to minimize waiting times and setup durations by strategically scheduling the use of empty changing table sets, employing mixed integer linear optimization to maximize throughput, and integrating fixed and variant setups to reduce refitting times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If changing tables are completely set up and refitted with components, then the pick-and-place line can produce different component types, but the setup time increases to hours and causes production downtime
Solution Approach 1:
The system performs pre-setup of changing tables in advance during periods when the pick-and-place line is operating. Multiple changing tables are prepared with different component types beforehand, so that when a setup change is needed, a pre-configured table can be quickly swapped in without stopping production for complete reconfiguration.
Solution Approach 2:
The setup process is divided into multiple changing tables that can be independently configured and prepared. Instead of one large setup operation, the system uses several smaller changing tables (e.g., 2-4 tables) that can be set up in parallel during production, reducing the impact on overall throughput.
2Adaptability or versatility
If changing tables are refitted with new components, then the line can accommodate new fabrication orders, but production downtime increases and throughput decreases
Solution Approach 1:
Changing tables are configured with components for upcoming fabrication orders in advance, during periods when the line is running other jobs. This allows the system to be ready for new orders without stopping production, maintaining high throughput while achieving order flexibility.
Solution Approach 2:
The system dynamically manages multiple changing tables with different component configurations, allowing flexible response to varying fabrication demands. Tables can be swapped in and out based on real-time production needs, enabling the line to adapt to different orders without complete shutdowns.
3Adaptability or versatility
If multiple changing tables are used for different setups, then component variety is available, but the complexity of managing and coordinating table setups increases
Solution Approach 1:
The control system continuously monitors the status of multiple changing tables and coordinates their setup and swapping operations. By implementing feedback loops that track table configuration states and production requirements, the system automatically optimizes table usage and minimizes manual coordination complexity.
Data Source
AI summary
A method and a control device for the throughput-optimized production of printed circuit boards on a pick-and-place line is provided. Further provided is a method for the throughput-optimized production of printed circuit boards on a pick-and-place line, wherein: the printed circuit boards are divided into groups known as clusters; each cluster is produced using one set-up; the set-up is realized by changing tables that can be attached to the pick-and-place line, each changing table having at least one feed device for keeping ready stocks of components; a quantity of changing tables needed for each set-up is referred to as a changing table set and an empty changing table set includes changing tables having feed devices that are empty.