Production Capacity Estimation for Component Mounting Lines
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Solution Overview
Problem
Existing methods for estimating production capacity in component mounting lines are prone to errors due to idealized assumptions and do not accurately reflect actual production performance, as they fail to account for device troubles and component shortages.
Innovation Solution
A production-capacity estimation apparatus that includes a memory storing floor-disposition, production-lot, and event information, along with an input unit for operator and production-plan data, which estimates production capacity based on these factors to provide a more precise prediction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing production capacity estimation methods are used, then the estimation process is simple, but the measurement precision is poor due to idealized assumptions that do not account for device troubles and component shortages
Solution Approach 1:
The system performs preliminary actions by pre-storing event information including device troubles and component shortages in the memory unit before production capacity estimation. This allows the estimation to account for real-world disruptions without complex real-time monitoring during the estimation process itself, thereby improving accuracy while maintaining manageable system complexity.
Solution Approach 2:
The system creates a virtual model (copy) of the production line that incorporates event information representing various disruption scenarios. This virtual model allows accurate estimation of production capacity under different conditions without requiring physical experimentation or complex real-time simulations, resolving the contradiction between accuracy and complexity.
2Measurement precision
If event information including device troubles and component shortages is incorporated, then the production capacity estimation accuracy is improved, but the information processing requirements increase
Solution Approach 1:
Event information is pre-collected and stored in the memory unit before the estimation process. This preliminary action organizes disruption data in advance, reducing the information processing load during actual estimation operations while maintaining high accuracy by having all necessary event data readily available.
Solution Approach 2:
The system serves itself by automatically managing and storing event information in its memory unit without requiring external intervention during the estimation process. This self-service approach to information management reduces processing overhead while ensuring accurate incorporation of disruption events into production capacity calculations.
Data Source
AI summary
A method is provided for estimating production capacity of a component mounting line for producing assembly boards. The component mounting line includes component-mounting-relevant devices coupled to one another, including a component mounter. Operator information is provided, which relates to an operator. Production-plan information is provided, which relates to a production plan for producing the assembly boards scheduled in the component mounting line. Based on floor-disposition information, production-lot information, event information, the operator information, and the production-plan information, a production capacity of the component mounting line is estimated. The floor-disposition information relates to a disposition of the component mounting line on a floor. The production-lot information relates to a time necessary for the component-mounting-relevant devices to produce the assembly boards. The event information relates to an event indicating that a work of the operator is necessary for the component-mounting-relevant devices and occurrence frequency indicating the number of occurrences of the event.