Production Sequence Planning Around Feeder Stock Constraints
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Solution Overview
Problem
Current production sequence optimization methods in production lines do not consider the number of resources held in stock, leading to increased downtime during setup operations due to the need for frequent feeder replacements and inefficient resource allocation.
Innovation Solution
A production sequence optimizing method and system that allocates resources such as feeders and nozzles based on stock availability, allowing for setup operations to be performed outside the production line, thereby reducing downtime by optimizing the execution order of production programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the editing application determines the execution order of production programs without considering the number of resources held in stock, then the production sequence is simple to determine, but the setup operation time increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-preparing feeders with tapes in advance outside the production line before the actual production program execution. The system determines the execution order of production programs while considering the number of feeders held in stock, and prepares the required number of feeders with their respective tapes beforehand. This allows setup operations to be performed outside the production line, reducing setup time while maintaining manageable complexity.
2Quantity of substance
If the number of feeders held in stock is limited, then the resource allocation is more constrained and manageable, but the ability to perform advance preparation of resources is reduced
Solution Approach 1:
The patent applies dynamics by making the production sequence determination adaptive to the actual number of feeders held in stock. The system dynamically adjusts the execution order of production programs based on the available feeder quantity, ensuring that the number of feeders required for advance preparation does not exceed the stock available. This dynamic adjustment allows effective resource preparation within the constraints of limited feeder inventory.
3Speed
If setup operations are performed inside the production line, then the resource replacement can be done quickly, but the production line must be stopped causing downtime
Solution Approach 1:
The patent applies the taking out principle by extracting the setup operation from the production line environment and performing it outside the production line. The system prepares the required number of feeders with tapes in advance outside the production line, then transfers them to the production line for execution. This separation allows setup operations to be performed without stopping the production line, maintaining production continuity while enabling quick resource replacement.
Data Source
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AI summary
An object is to provide a production sequence optimizing method and a production sequence optimizing system that can reduce downtime caused by a setup operation. A production sequence optimizing method classifies a plurality of production programs which are continuously executed using a production line (L) into a plurality of groups which share resources (42, 320) used for production and optimizes an execution order of the plurality of production programs. The production sequence optimizing method includes: a resource number counting step of counting the number of all resources (42, 320) held in stock; and a resource allocation step of allocating the resources (42, 320) to each of the groups on the basis of the number of all resources (42, 320), the number of resources (42, 320) required for an N-th (N is a natural number) group, and the number of resources (42, 320) required for an (N+1)-th group.