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User Manual Line Computer UNIX 11 Production Tools / Optimization Software Version 501.xx 01/99 Issue 11.4 Optimization Dialog 11 - 29 Effect: From the i nitial s etup a fol low-up s etup is c omputed i n the shor test p…
11 Production Tools / Optimization User Manual Line Computer UNIX
11.4 Optimization Dialog Software Version 501.xx 01/99 Issue
11 - 28
11.4.3.2 Examples of Parameter Settings
The parameter settings for Set-Up Optimization greatly depend on the frequency of setup changeover
operations taking place during a production run.
Three examples have been selected to show how the parameters can be set in different production situations:
● highly flexible production: many different jobs are processed in a very short time with the setup
changeover operations required.
● flexible production: frequent setup changeover operations are carried out whereby identical jobs are
also processed over and over.
● inflexible production: only one single setup is used for production over a long period of time.
Example 1: Highly flexible production
Setup problem:
In the case of a highly flexible production, setup changeover operations are performed daily in order to
produce new products. Setup changeover is carried out job-specifically.
Objective:
A setup is to be calculated for a given job as fast as possible. As little time as possible is to be expended
on the setup changeover. Production time plays is of minor importance.
Parameter settings:
● Clustering according to the Sequence method.
● Maximum number (feeders) if dominant: 1.
● No. of iteration steps: 1
(With a setting of 0 one single setup is created. It is, however, not optimized. This is the fastest
method for obtaining a setup.).
Lot file setting:
● Set the lot size to 1 so that only the setup changeover time is of importance.
● Enter an initial setup, i.e. the current setup of the line.
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 501.xx 01/99 Issue 11.4 Optimization Dialog
11 - 29
Effect:
From the initial setup a follow-up setup is computed in the shortest possible amount of time, having the
following features:
● A minimum changeover time from the initial setup to the follow-up setup is achieved.
● Every component is set up only once. The dominance of components is suppressed.
● Feeders with two compartments that are taken over from the initial setup and integrated into the
follow-up setup remain set up on the exactly same tracks as before.
● Components of the initial setup that are not required remain at their location.
Example 2: Flexible production
Setup problem:
In the case of flexible production, frequent setup changeover operations are performed with identical jobs
also being produced over and over again. Planning is medium-term.
Objective:
Grouping of products into setup families with the focus on short production times. Setup changeover
operations should be limited to changeover tables as far as possible.
Parameter settings:
● Clustering according to the Mean value method.
● Maximum number (feeders) if dominant: 2.
● Number of iteration steps: 5.
Lot file setting:
● The lot size is to be set to a realistic value.
● Enter a fixed setup, if desired.
Effect:
In a medium amount of time a setup or a setup family is calculated having the following features:
● Changeover time is taken into account depending on the lot size.
● Changeover operations are limited to the changeover trolleys (where configured).
● Production time is optimized. A compromise between production time and changeover time is
reached.
11 Production Tools / Optimization User Manual Line Computer UNIX
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Example 3: Inflexible production
Setup problem:
In the case of inflexible production, only one setup is used for production over a long period of time.
Objective:
One single setup is to be calculated whereby the products should be utilized to 100% capacity, if possible.
Parameter settings:
● Clustering is not important as only one setup is to be calculated.
● Maximum number (feeders) if dominant: 0. (Set-Up Optimization is to decide on its own how often the
components are to be set up.)
● Board Booster: Program run time per lot: e.g. 43200 sec (= 12 hours). The computation may be car-
ried out over night and will then be available the next morning by the start of the first shift.
Lot file setting:
● The lot size is to be set to a realistic value.
● Do not enter any initial setup nor fixed setup.
Effect:
The best possible setup is calculated within the stated program run time.
11.4.3.3 Changing Job Parameters
If neither the default values nor the standard values are to be used for the optimization of a given lot file, it is
possible to set the job parameters for this lot file. The job parameters are valid for the optimization of this one
lot file only. For a description of the individual parameters, see section 11.4.3.1.
Procedure:
● Click on a lot file.
● On the SERVICES menu click on the Change job parameters option.
The „Change job parameters for xx.lose“ window opens.
● Change the job parameters.
11.4.3.4 Discarding Job Parameters
The job parameters for a lot file that were set by the customer can be deleted. The standard parameters are
then relevant to this lot file again.
Procedure:
● Click on a lot file.
● On the SERVICES menu click on the Discard job parameters option.
The job parameters are deleted for this lot file. No verification query occurs.