Setup Change Time Visualization for Board Production Lines
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Solution Overview
Problem
In board production facilities, the increasing number of steps in setup changing work reduces the operating ratio, and there is a need for visualizing the execution time zone of this work.
Innovation Solution
An operation state display device and method that acquire and graphically display the execution time zone for setup changing work in board production facilities, allowing for visualization of the time series in which this work is performed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of steps in setup changing work is increased to improve production flexibility, then adaptability is improved, but the operating ratio deteriorates due to increased setup time
Solution Approach 1:
The system performs preliminary actions by acquiring and analyzing production information before setup changing work begins. It predicts the execution time zone in advance and displays it to operators, allowing them to prepare accordingly and potentially overlap preparation activities with production activities, thereby reducing actual setup time while maintaining flexibility
Solution Approach 2:
The system implements feedback by continuously monitoring actual setup execution time and comparing it with predicted time. This feedback loop allows for real-time adjustments and continuous improvement of setup processes, helping to reduce setup time while maintaining the necessary number of steps for production flexibility
2Adaptability or versatility
If setup changing work steps are increased to handle product type switching, then adaptability is improved, but loss of time increases due to extended setup duration
Solution Approach 1:
The system acquires production information in advance and predicts the execution time zone for setup changing work before it actually occurs. This preliminary analysis allows operators to prepare necessary materials, tools, and procedures ahead of time, reducing the actual time spent on setup while maintaining the required number of steps for handling different product types
Solution Approach 2:
The system dynamically adjusts the display and analysis of setup time based on actual production conditions and historical data. It can adapt the predicted execution time zone according to varying production requirements, allowing flexible optimization of setup processes while maintaining adaptability to different product types
3Measurement precision
If detailed production information is collected and analyzed, then measurement precision is improved, but device complexity increases due to additional acquisition and analysis functions
Solution Approach 1:
The display device is designed with multi-functionality, serving both as a production information acquisition system and as a setup time prediction and display system. By integrating multiple functions into a single device, the system achieves high measurement precision for setup time while avoiding the complexity of separate dedicated systems for each function
Data Source
AI summary
An operation state display device displays an operation state of a board production facility in which a board is sequentially conveyed to multiple board work machines, which perform predetermined board work on the board, and the board work is sequentially performed to produce a board product, and includes an acquisition section and a display section. The acquisition section acquires an execution time zone in which setup changing work required for switching a type of the board product to be produced is performed, for each board work machine, based on production information acquired by the board production facility during production of the board product. The display section graphically displays at least one of the execution time zone for each of the multiple board work machines and the execution time zone for a predetermined board work machine of the board production facility in time series.