Work Instruction Derivation for Component Mounter Setup Changeover
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Solution Overview
Problem
In component mounting systems, setup changeover work for switching between substrate types is complex and inefficient, particularly for low-skilled workers, as they struggle to recognize the correct work execution sequence, leading to difficulties in executing setup changeover work efficiently and easily.
Innovation Solution
A method and system that derive and display work instruction information on a display screen, including unit work information with kind and feeder state information, to guide workers through the setup changeover process, ensuring the correct sequence of operations for changing the arrangement state of parts feeders from a current to a first arrangement state for a scheduled substrate type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a worker executes setup changeover work by checking a work instruction table, then the substrate type can be changed, but the work becomes complicated and inefficient
Solution Approach 1:
The patent segments the setup changeover work into discrete unit work items, each representing a specific action (e.g., detach feeder A, attach feeder B). These segmented tasks are then displayed in chronological order on the display screen, transforming a complex overall task into manageable sequential steps that reduce worker cognitive load and improve ease of operation.
Solution Approach 2:
The system performs preliminary actions by automatically generating the work instruction information before the worker begins execution. The instruction information is prepared in advance based on the current feeder arrangement and the target substrate requirements, so when the worker starts the changeover, clear guidance is already available, reducing the complexity of planning and execution.
2Adaptability or versatility
If many feeders are detached and moved to new positions, then the component supply can be adapted to new substrate types, but the work execution sequence becomes difficult to recognize
Solution Approach 1:
The system performs preliminary action by pre-calculating and displaying the complete work execution sequence before the worker begins. The display screen shows all required feeder detachment and attachment operations in the correct chronological order, ensuring the worker has full sequence information available in advance, preventing information loss during execution.
Solution Approach 2:
The system provides feedback by displaying the work instruction information that reflects the actual state changes required. As the worker completes each unit work item, the system maintains information about the current arrangement state, ensuring the displayed instructions remain accurate and synchronized with the physical state of the feeder arrangement.
3Productivity
If setup changeover work instructions are displayed on a screen, then work efficiency can be improved, but low-skilled workers still struggle to recognize the correct sequence
Solution Approach 1:
The patent divides the changeover work into finely segmented unit work items that are displayed sequentially on the screen. Each unit work item represents a single, clear action rather than a complex multi-step process. This segmentation makes the information easily digestible for low-skilled workers, allowing them to focus on one simple task at a time while maintaining overall productivity.
Solution Approach 2:
The system performs preliminary action by preparing and displaying the complete segmented work sequence before execution begins. The display screen shows all unit work items in the correct order in advance, so low-skilled workers can see the entire sequence and understand what needs to be done without having to recognize or plan the sequence themselves during execution.
Data Source
AI summary
A component mounting system derives work instruction information defining setup changeover work necessary to change an arrangement state of parts feeders from a current arrangement state to a first arrangement state for producing a first substrate type based on current feeder arrangement information corresponding to the current arrangement state and first feeder arrangement information corresponding to the first arrangement state. The work instruction information includes a plurality of pieces of unit work information. Each of the pieces of the unit work information includes kind information indicating a kind of execution operation and feeder state information indicating states before and after execution of work on the parts feeder targeted in the setup changeover work. The pieces of unit work information are displayed on the display screen so as to be arranged in work sequence to be executed.