Production sequence optimizing method and production sequence optimizing system

• US 10,139,813 B2
• Filed: 09/12/2012
• Issued: 11/27/2018
• Est. Priority Date: 09/12/2012
• Status: Active Grant

• Current Assignee: Fuji Company Limited
• Original Assignee: Fuji Company Limited
• Inventors: Morita, Yukitoshi
• Primary Examiner(s): Fennema, Robert E
• Assistant Examiner(s): Foley, Shon G
• Application Number:
  US14/427,410
• Publication Number:
  US 20150248314A1
• Time in Patent Office: 2,267 Days
• Field of Search: 700 99
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32264 Setup time
• CPC Class Codes: G05B 2219/32283 Machine scheduling, several machines, several jobs
• CPC Class Codes: G05B 2219/32291 Task sequence optimization
• CPC Class Codes: G05B 2219/32298 Designate at least two group of articles, first with priority, reschedule second
• CPC Class Codes: G05B 2219/45026 Circuit board, pcb
• CPC Class Codes: G06F 9/4881 Scheduling strategies for dispatcher, e.g. round robin, multi-level priority queues
• CPC Class Codes: G06F 9/5044 considering hardware capabilities
• CPC Class Codes: H05K 13/08 Monitoring manufacture of assemblages
• CPC Class Codes: H05K 13/085 Production planning, e.g. of allocation of products to machines, of mounting sequences at machine or facility level
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A production sequence optimizing method and a production sequence optimizing system that can reduce downtime caused by a setup operation. The production sequence optimizing method classifies a plurality of production programs which are continuously executed using a production line into a plurality of groups which share resources used for production and optimizes an execution order of the plurality of production programs. The production sequence optimizing method includes: a resource number counting step of counting the number of all resources held in stock; and a resource allocation step of allocating the resources to each of the groups on the basis of the number of all resources, the number of resources required for an N-th group, and the number of resources required for an (N+1)-th group.

Claims

1. A production sequence optimizing method that classifies a plurality of production programs which are continuously executed using a production line into a plurality of groups which share resources used for production and that optimizes an execution order of the plurality of production programs, comprising:

a resource number counting step of counting a number of all resources held in stock; and

a resource allocation step of, in a case where the number of all resources is less than a sum of a number of resources required for an N-th group and a number of resources required for an (N+1)-th group where N is a natural number, allocating the resources to each of the groups on the basis of the number of all resources, the number of resources required for the N-th group, and the number of resources required for the (N+1)-th group, wherein

the resources include feeders, each including a tape having electronic components and being detachably provided in an electronic component mounting machine,

when the feeders are individually replaced in the electronic component mounting machine in a first setup operation, the feeders are allocated to each of the groups in the resource allocation step in a first manner, and

when the feeders are collectively replaced in the electronic component mounting machine in a second setup operation different from the first setup operation, the feeders are allocated to each of the groups in the resource allocation step in a second manner different from the first manner.

2. The production sequence optimizing method according to claim 1, wherein, in the first manner,

the feeders are allocated to each of the groups in the resource allocation step using the following Expression (1):

X0−

X1+X3 ≥

X2 

 

Expression (1),

where X0 is a number of all feeders, X1 is a number of feeders required for the N-th group, X2 is a number of feeders required for the (N+1)-th group, and X3 is a number of feeders shared by the N-th group and the (N+1)-th group.

3. The production sequence optimizing method according to claim 1, wherein, in the second manner,

the feeders are allocated to each of the groups in the resource allocation step using the following Expression (2):

X1+X2≤

X0 

 

Expression (2),

where X0 is a number of all feeders, X1 is a number of feeders required for the N-th group, and X2 is a number of feeders required for the (N+1)-th group.

4. The production sequence optimizing method according to claim 1, wherein

the resources further include nozzles, each being detachably provided in the electronic component mounting machine and configured to transfer an electronic component, and

the nozzles are allocated to each of the groups in the resource allocation step using the following Expression (3):

Y1+Y2≤

Y0 

 

Expression (3),

where Y0 is a number of all nozzles, Y1 is a number of nozzles required for the N-th group, and Y2 is a number of nozzles required for the (N+1)-th group.

5. The production sequence optimizing method according to claim 1, further comprising:

a reference optimization step of allocating the resources to a production program with a highest priority among the plurality of production programs such that a cycle time is shortened before the resource allocation step.

6. The production sequence optimizing method according to claim 5, further comprising:

reducing a number of the resources in a group that includes the production program with the highest priority when the resource allocation is not appropriate.

7. The production sequence optimizing method according to claim 1, further comprising:

reducing a number of production programs in one group when the resource allocation is not appropriate.

8. A production sequence optimizing system comprising:

a production line including an electronic component mounting machine configured to put electronic components on a board; and

a control device that classifies a plurality of production programs which are continuously executed using the production line into a plurality of groups which share resources used for production and optimizes an execution order of the plurality of production programs,

wherein the control device is configured to perform;

a resource number counting step of counting a number of all resources held in stock; and

a resource allocation step of, in a case where the number of all resources is less than a sum of a number of resources required for an N-th group and a number of resources required for an (N+1)-th group where N is a natural number, allocating the resources to each of the groups on the basis of the number of all resources, the number of resources required for the N-th group, and the number of resources required for the (N+1)-th group, wherein

the resources include feeders, each including a tape having the electronic components and being detachably provided in the electronic component mounting machine,

when the feeders are individually replaced in the electronic component mounting machine in a first setup operation, the feeders are allocated to each of the groups in the resource allocation step in a first manner, and

when the feeders are collectively replaced in the electronic component mounting machine in a second setup operation different from the first setup operation, the feeders are allocated to each of the groups in the resource allocation step in a second manner different from the first manner.

9. The production sequence optimizing system according to claim 8, wherein, in the first manner,

the control device allocates the feeders to each of the groups in the resource allocation step using the following Expression (1):

X0−

X1+X3≥

X2 

 

Expression (1),

where X0 is a number of all feeders, X1 is a number of feeders required for the N-th group, X2 is a number of feeders required for the (N+1)-th group, and X3 is a number of feeders shared by the N-th group and the (N+1)-th group.

10. The production sequence optimizing system according to claim 8, wherein, in the second manner,

the control device allocates the feeders to each of the groups in the resource allocation step using the following Expression (2):

X1+X2 ≤

X0 

 

Expression (2),

where X0 is a number of all feeders, X1 is a number of feeders required for the N-th (N is a natural number) group, and X2 is a number of feeders required for the (N+1)-th group.

11. The production sequence optimizing system according to claim 8, wherein

the resources further include nozzles, each being detachably provided in the electronic component mounting machine and configured to transfer the electronic components, and

the control device allocates the nozzles to each of the groups in the resource allocation step using the following Expression (3):

Y1+Y2≤

Y0 

 

Expression (3),

where Y0 is a number of all nozzles, Y1 is a number of nozzles required for the N-th group, Y2 is a number of nozzles required for the (N+1)-th group.

12. The production sequence optimizing system according to claim 8, wherein the control device performs a reference optimization step of allocating the resources to a production program with a highest priority among the plurality of production programs such that a cycle time is shortened before the resource allocation step.

13. The production sequence optimizing system according to claim 12, wherein the control device reduces a number of the resources in a group that includes the production program with the highest priority when the resource allocation is not appropriate.

14. The production sequence optimizing system according to claim 8, wherein the control device reduces a number of production programs in one group when the resource allocation is not appropriate.