Substrate Production Simulation for Operator Delay Visibility
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Solution Overview
Problem
Existing substrate production simulation methods cannot accurately identify delays caused by operator operations, making it impossible to optimize the number of operators to prevent process delays.
Innovation Solution
A simulation method that compares production scenarios with and without delays in component supply by automated facilities or workers, outputting results on the same screen to easily identify delays attributed to either automated facilities or workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional simulation methods calculate operator load factors and throughput, then layout design can consider operator arrangement, but delay in process by operator operations cannot be grasped
Solution Approach 1:
The patent segments the simulation into two distinct scenarios: one assuming instantaneous component supply (ideal case) and another incorporating actual automated facility and worker operations (realistic case). This segmentation allows separate analysis of each scenario's impact on production timing, enabling identification of delays caused by operational factors.
Solution Approach 2:
The patent introduces an intermediary comparison mechanism that overlays results from both simulation scenarios. By presenting both the ideal and realistic simulation outcomes together, the system mediates between theoretical performance and actual operational constraints, making delays visible and attributable to specific operational factors.
2Productivity
If it is not possible to set the number of operators to cancel process delay, then production efficiency cannot be optimized, but adding more operators increases cost and complexity
Solution Approach 1:
The patent implements a feedback mechanism where simulation results showing production delays are fed back to the layout design stage. This feedback loop enables iterative optimization of operator numbers and arrangements before actual implementation, allowing productivity optimization without requiring complex real-time adjustments or excessive operator numbers.
Solution Approach 2:
The patent performs preliminary simulation and analysis during the layout design phase, before actual production begins. By predicting and addressing potential delays in advance through simulation, the system enables proactive optimization of operator配置 (configuration) rather than reactive adjustments, reducing the need for excessive operators to compensate for unoptimized processes.
3Measurement precision
If simulation results are presented separately, then detailed analysis is possible, but easy confirmation of delays caused by automated facilities or workers is difficult
Solution Approach 1:
The patent merges the presentation of two separate simulation results into a unified visual format. By displaying both the ideal scenario (instantaneous supply) and realistic scenario (actual operations) on the same screen with synchronized timing, the system combines detailed analytical capability with ease of comparison, allowing users to quickly identify delays while maintaining precise measurement capability.
Data Source
AI summary
In a substrate production simulation method, production of a product substrate on which mounting of a component supplied from a component supply device is completed is simulated using a substrate production line including a mounting line in which multiple component mounters for mounting the component on a substrate are arranged. The method includes steps (a) to (c). In the step (a), a first result is obtained by simulation on the assumption that provision and collection of the component supply device with respect to the substrate production line are performed without delay. In the step (b), a second result is obtained by simulation on the assumption that provision and/or collection of the component supply device with respect to the substrate production line is performed by an automated facility and/or a worker. In the step (c), the first result and the second result are output to the same screen in a form indicating a transition of a production number of product substrates with respect to time.