Setup Change Task Setting for Component Mounter Wheeled Tables
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Solution Overview
Problem
Inefficient setup change tasks for wheeled tables in component mounters lead to extended stop times and decreased productivity, especially for inexperienced operators and when inventory constraints are present, as current methods rely on intuition and experience rather than systematic approaches.
Innovation Solution
A setup change task setting device that acquires the number of feeders required to be replaced and compares the relative merits of different setup change tasks based on evaluation scales such as stop time and degree of utilization, allowing for the automatic selection of an optimal setup change task for wheeled tables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If setup change tasks are set based on intuition or experience, then skilled operators can achieve reasonable efficiency, but inexperienced operators cannot set efficient tasks leading to extended stop times and decreased productivity
Solution Approach 1:
The system performs self-service by automatically determining the optimal setup change task type without requiring operator expertise. The determination unit autonomously analyzes feeder replacement requirements and selects the most efficient task type (internal setup work, exchange work, or mixing work), eliminating dependence on operator intuition or experience while maximizing productivity.
Solution Approach 2:
The system changes the parameter of task selection from subjective operator judgment to objective automated determination. By analyzing quantitative parameters such as the number of feeders to be replaced and comparing it against predefined thresholds, the system dynamically selects the optimal task type, transforming an experience-based decision into a data-driven automated process.
2Quantity of substance
If the number of wheeled tables is constrained, then inventory management is improved, but it becomes further difficult to set efficient setup change tasks
Solution Approach 1:
The system introduces dynamics by adaptively adjusting the setup change task selection based on the constrained number of wheeled tables. The determination unit considers the available wheeled table inventory and dynamically selects from multiple task types (internal setup work, exchange work, mixing work) to optimize productivity within the given constraints, rather than using a fixed approach.
Solution Approach 2:
The system performs preliminary action by pre-planning the setup change task selection before actual execution. The determination unit calculates the optimal task type in advance based on the number of feeders to be replaced and the constrained wheeled table inventory, ensuring that productivity is maximized while respecting inventory limitations before the setup change begins.
3Adaptability or versatility
If multiple types of setup change tasks are available, then flexibility in task selection is improved, but the complexity of determining the optimal task increases
Solution Approach 1:
The system applies segmentation by dividing the complex task selection process into distinct, manageable task types: internal setup work (when feeders are replaced within the component mounter), exchange work (when wheeled tables are exchanged), and mixing work (combination of both). This segmentation simplifies the determination logic by providing clear decision criteria for each task type based on the number of feeders to be replaced and wheeled table availability.
Data Source
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AI summary
A setup change task setting device includes a number-of-feeders acquisition section configured to acquire the number of feeders required to be replaced in a wheeled table on which multiple feeders supplying components are installed to be replaceable during a setup change in which a board on which the components are mounted is changed from a current board type to a next board type in a component mounter in which the wheeled table is provided to be exchangeable, a task comparing section configured to compare relative merits of multiple types of setup change tasks in the wheeled table provided in the component mounter based on an acquisition result from the number-of-feeders acquisition section, and a task setting section configured to set any of the multiple types of setup change tasks for the wheeled table based on a comparison result from the task comparing section.