Production Sequencing for Balanced Off-Line Setup Time
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Solution Overview
Problem
Existing production support systems fail to minimize operation stop time between groups in a production sequence due to not considering off-line setup time, which is not always proportional to component installation time.
Innovation Solution
A production management device determines a production sequence that balances the sum of off-line setup times for consecutively produced substrates by alternately arranging substrates with longer and shorter off-line setup times, and by arranging substrates with a larger and smaller number of necessary attachment plates to minimize the number of plates used simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the production sequence is determined by balancing component installation time, then the total component installation time for adjacent groups is balanced, but the operation stop time between groups is not reduced
Solution Approach 1:
The patent changes the scheduling parameter from component installation time to off-line setup time. By using off-line setup time as the basis for determining production sequence and balancing adjacent groups, the system addresses the root cause of operation stop time. This parameter change resolves the contradiction because off-line setup time directly correlates with machine preparation requirements and cart changes, which are the actual causes of operation stops.
2Reliability
If substrates with longer off-line setup time are produced first, then the off-line setup can be completed before production starts, but machine operation stop occurs when off-line setup time exceeds production time
Solution Approach 1:
The patent implements periodic action by alternately arranging substrates with longer and shorter off-line setup times in the production sequence. This alternating pattern ensures that off-line setup times for adjacent groups are balanced, preventing any single group's setup time from exceeding the production time of the previous group. This periodic arrangement maintains both reliable setup completion and continuous machine operation.
Solution Approach 2:
The patent applies preliminary action by completing off-line setup for the next substrate group before the current group's production is fully completed. By balancing off-line setup times, the system ensures that setup work is prepared in advance without causing operation stops, as the setup time is guaranteed to be within the production time of the preceding group.
3Quantity of substance
If the number of attachment plates is minimized, then the number of carts to be used is reduced, but the flexibility to handle different product types is limited
Solution Approach 1:
The patent applies dynamics by optimizing the attachment plate arrangement based on the specific production sequence and product types being manufactured. Rather than using a fixed maximum number of plates, the system dynamically determines the minimum required plates for each production phase while maintaining the capability to handle different product types through balanced sequencing. This allows flexibility to be achieved through intelligent scheduling rather than physical redundancy.
Data Source
AI summary
A production management device, such as a production management computer, determines a production sequence of plural types of substrates in order to produce the substrates consecutively on a product type-by-type basis by using a component mounter including component supply devices. The production management device includes a main control unit for determining a production sequence of substrates such that, where a time from start to completion of off-line setup of all the component supply devices to be used for a single product type of substrate is defined as an off-line setup time, a sum of the off-line setup times for two product types of substrates to be consecutively produced is balanced over an entire period of consecutive production.