PRODUCTION SEQUENCE OPTIMIZING METHOD AND PRODUCTION SEQUENCE OPTIMIZING SYSTEM

• US 20150248314A1
• Filed: 09/12/2012
• Published: 09/03/2015
• Est. Priority Date: 09/12/2012
• Status: Active Grant

• Current Assignee: Fuji Company Limited
• Original Assignee: Fuji Machine Manufacturing Company Limited
• Inventors: Morita, Yukitoshi
• Granted Patent: US 10,139,813 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 the a 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, 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.

2. The production sequence optimizing method according to claim 1,

wherein each resource is a feeder including a tape having electronic components and the feeder is detachably provided in an electronic component mounting machine,

when the feeders are individually replaced in the electronic component mounting machine in a setup operation, 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 each resource is a feeder including a tape having electronic components and the feeder is detachably provided in an electronic component mounting machine,

when the feeders are collectively replaced in the electronic component mounting machine in a setup operation, 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 each resource is a nozzle which is detachably provided in the electronic component mounting machine and transfers the electronic component,

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

6. A production sequence optimizing system comprising:

a production line; 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 performs;

a resource number counting step of counting a 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, 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.

7. The production sequence optimizing system according to claim 6,

wherein the production line includes an electronic component mounting machine that puts electronic components on a board,

each resource is a feeder including a tape having electronic components and the feeder is detachably provided in the electronic component mounting machine, and

when the feeders are individually replaced in the electronic component mounting machine in a setup operation, 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.

8. The production sequence optimizing system according to claim 6,

wherein the production line includes an electronic component mounting machine that puts electronic components on a board,

each resource is a feeder including a tape having electronic components and the feeder detachably provided in the electronic component mounting machine,

when the feeders are collectively replaced in the electronic component mounting machine in a setup operation, 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.

9. The production sequence optimizing system according to claim 6,

wherein the production line includes an electronic component mounting machine that puts electronic components on a board,

the resource is a nozzle which is detachably provided in the electronic component mounting machine and transfers 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.

10. The production sequence optimizing system according to claim 6,

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