Component Replenishment Management System for SMT Lines
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Solution Overview
Problem
Existing component replenishment systems in component mounting lines require frequent operator intervention at individual component mounters due to individually set replenishment timings, leading to inefficient component replenishment work.
Innovation Solution
A component replenishment management system that identifies emergency devices based on set component replenishment time limits, sets an emergency time zone, and prioritizes replenishment targets within this zone to optimize operator movement and reduce frequency of visits to component mounters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If component replenishment timing is set individually for each component supply device, then the component supply can be maintained without interruption, but the operator needs to visit component mounters with high frequency and cannot perform replenishment work efficiently
Solution Approach 1:
The patent merges multiple individual replenishment tasks into a single comprehensive replenishment plan. The component replenishment management system aggregates replenishment requests from multiple component supply devices across different component mounters and consolidates them into unified replenishment targets that can be serviced in batches, transforming numerous individual operator visits into fewer consolidated visits.
Solution Approach 2:
The system performs preliminary analysis of component consumption trends and replenishment requirements before actual replenishment is needed. By predicting future replenishment needs and preparing consolidated replenishment plans in advance, the system enables operators to perform replenishment work more efficiently without compromising component supply continuity.
2Reliability
If operator visits component mounters frequently to perform replenishment work, then component supply continuity is maintained, but time is lost due to frequent movements and the replenishment work cannot be performed efficiently
Solution Approach 1:
The patent combines multiple scattered replenishment tasks into consolidated replenishment operations. By aggregating replenishment requests from multiple component supply devices and mounters into unified replenishment targets, the system reduces the total number of operator visits required, thereby minimizing time loss due to frequent movements while maintaining component supply continuity.
Solution Approach 2:
The system continuously monitors component consumption levels and replenishment status, providing real-time feedback to optimize replenishment scheduling. This feedback mechanism enables the system to adjust replenishment plans dynamically, ensuring component supply continuity while minimizing unnecessary operator visits and time loss.
3Reliability
If component replenishment work is performed according to individually set replenishment timing for each component supply device, then each device can be replenished on time, but the overall replenishment work efficiency is reduced due to scattered operations
Solution Approach 1:
The patent merges individually scheduled replenishment tasks into consolidated replenishment operations. The component replenishment management system aggregates replenishment requests from multiple component supply devices and determines unified replenishment targets and timing, maintaining accurate replenishment schedules while improving overall work efficiency by reducing scattered operations.
Solution Approach 2:
The system dynamically adjusts replenishment plans based on real-time component consumption data and operational status. By making replenishment scheduling flexible and adaptive rather than rigid and predetermined, the system can maintain accurate replenishment timing while optimizing operator routes and consolidating tasks to improve overall efficiency.
Data Source
AI summary
A component replenishment management system includes an emergency device extraction unit, an emergency time setting unit, a replenishable device identification unit, and a replenishment target extraction unit. The emergency device extraction unit extracts, as first and second emergency devices, top two component supply devices having highest degree of emergency for performing the component replenishment work. The emergency time setting unit sets an emergency time zone from a first emergency time for the component replenishment work for the first emergency device to a second emergency time for the component replenishment work for the second emergency device. The replenishable device identification unit identifies, as a replenishable device, a component supply device that can be replenished with a component storage member. The replenishment target extraction unit extracts a replenishment target device that is a target of the component replenishment work within a range of the emergency time zone among the replenishable devices.