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User’s Manual Line Computer UNIX 11 Production Tools / Optimization Software Version 402.xx Edition 06/96 11.3 Setup Optimization 11 - 9 11.3.3.2 Fixe d Setup It is po ssible for the op erator to predete rmine a fixe d s…
11 Production Tools / Optimization User’s Manual Line Computer UNIX
11.3 Setup Optimization Software Version 402.xx Edition 06/96
11 - 8
Once the file has been successfully compiled, i.e. the setup data for one or several optimized setups have
been created, the lot file will be identified as „optimized“. If the lot file could not be compiled due to errors,
the lot file will be identified as „faulty“. An „.error“ error file will be created under the path of the lot file in
which the causes of the errors are displayed (see section 11.3.4).
☞
NOTE
The file
xx01.ar
generated by the Setup Optimization is stored in the master data, in the path
Anlagen/<Line>.ak/<Subline>.va/*
. The data can be viewed in the main window of the Setup Modification
Generator (see chapt. 14) and can be output to the printer.
11.3.3 Functions of the Setup Optimization
The subsections in the following provide an explanation of the parameters influencing Setup Optimization, or
which are taken into account for Setup Optimization.
11.3.3.1 Control of the Setup Optimization by the Operator
To control Setup Optimization, the operator can edit the following files by means of the appropriate editors and
thus influence the Setup Optimization program:
-
Lot file xx.lose Fixed setup --> PCBs --> line --> subline (see chapt. 14)
-
Setup info file .ri Type bindings (see chapt. 9)
(Feeder Editor) (The Setup info file contains the allocations of
Component -> Feeder -> Machine type,
Component -> Feeder,
Package form -> Machine type -> Feeder and
Package form -> Feeder).
-
Restriction file .rs Individual bindings (see chapt. 10)
(The Restriction file contains, for example, information on
components "bound" to specific feeder parts).
-
Parameter file Standard.Def to define the standard parameters
OPP.Def to define the job-specific optimization parameters
User’s Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 402.xx Edition 06/96 11.3 Setup Optimization
11 - 9
11.3.3.2 Fixed Setup
It is possible for the operator to predetermine a fixed setup (ff.ar) for optimization. This fixed setup is taken over
without restrictions.
●
Each component of the fixed setup including the specified track is integrated into the new setup
irrespective of whether the component is required by the preset PCB types or not.
●
Partly set up feeders of the fixed setup are not allocated.
(Partly set up signifies that, for example, on a feeder comprising two compartments only one compartment
is occupied).
●
A component type that is already contained in the fixed setup can be set up by set-up optimization as often
as required for the optimum setup. However, it is also possible to specify that a fixed set up component
type must not be set up a second time regardless whether an even better result would be achieved. This
setting is made in the standard parameters (see section 11.4.3.1).
11.3.3.3 Initial Setup
The operator can preset an initial setup (aa.ar) in the lot file. Optimization tries to adopt as many components
as possible from the initial setup, track-for-track. Components from the initial setup that are not required are
removed from the setup. The number of components that are adopted track-for-track depends on the lot size
entered.
Effects:
-
Large lot size:
-
production time is of importance,
-
setup changeover operations are permitted if they result in a reduction of production time,
-
few components are adopted from the initial setup.
-
Small lot size:
-
setup changeover time is of importance,
-
setup changeover operations to be kept to a minimum,
-
as many components as possible to be adopted from the initial setup.
Effect of the Lot Size on the Optimization Results
The effect of the lot size can be expressed using the following formula:
Machine run time saving = production time saving - setup changeover time
Production time saving = lot size x (old production time - new production time)
Production time saving with respect to one setup changeover operation = old production time - new
production time
11 Production Tools / Optimization User’s Manual Line Computer UNIX
11.3 Setup Optimization Software Version 402.xx Edition 06/96
11 - 10
The following two examples will demonstrate the importance of a realistic lot size.
Example 1:
Lot size = 1
Changeover time per feeder = 60 sec
Production time = 60 sec
For a feeder setup changeover to make sense, the production time gain must be at least 60 sec. This is
impossible in example 1.
Example 2:
Lot size = 100 (or 100 lots with lot size 1)
Changeover time per feeder: = 60 sec
Production time per lot = 60 sec
In this case, a feeder setup changeover would be sensible already with a production time gain of 1 sec. per
lot, as this results in a machine run rime saving of 40 sec.
11.3.3.4 Station Setup by Setup Optimization
Setup of Nozzle Changer (IC-Head or Turret Head)
If an empty Nozzle Changer is allocated to a configured station, Setup Optimization will assign to the Nozzle
Changer all nozzles required for the placement of the components contained in the particular setup.
If a completely set up Nozzle Changer is allocated to the configured station (see chapt. 12), Setup Optimization
performs a check as to whether all components contained in the setup can be placed by means of the assigned
nozzles. If not, the Nozzle Changer is converted by Setup Optimization.
●
Conversion Criteria
(if nozzles are missing)
1.
The additionally required nozzles are assigned to the free compartments of the Nozzle Changer.
2.
Setup Optimization attempts to place all the other required nozzles into compartments which are
occupied by a nozzle type which is available in the Nozzle Changer several times.
Example:
If compartments 2 and 4 have been assigned nozzle type "316", Setup Optimization
tries to place the required nozzle type into compartment 2 or 4.
3.
Setup Optimization replaces all nozzles that have been allocated to the Nozzle Changer but are
not required, with nozzles that have not yet been set up but are required for the particular setup.