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11 Production Tools / Optimization User Manual Line Computer UNIX 11.4 Optimization Dial og Software Version 501.xx 01/99 Issue 11 - 30 Example 3: Inflexible production Setup problem: In the cas e of infle xible pr oduct…
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
11.4 Optimization Dialog Software Version 501.xx 01/99 Issue
11 - 30
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.
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 501.xx 01/99 Issue 11.4 Optimization Dialog
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11.4.3.5 Viewing the Error File
If errors occur during the optimization of a lot file, the optimization process is aborted and an error file is created.
This error file can be displayed using the file display option. This window contains a listing of all errors that
occurred during the optimization run (see also chapt. 4).
After the errors are eliminated a new optimization run for the given lot file can be started.
Procedure:
● Click on a lot file identified as „faulty“.
● On the SERVICES menu click on the Viewing error file option, or double-click on the faulty lot file.
The file display window containing the error messages is opened.
11.4.3.6 Starting the Feeder Editor
In the Feeder Editor it is possible to globally define for the line allocations of components and package forms
to given feeders and waffle-pack trays. Any faulty or missing allocations that were determined in an optimization
run can, at this point, be corrected or newly defined (see chapt. 9).
Procedure:
● On the SERVICES menu click on the Starting Feeder Editor option.
The Feeder Editor is started.
11.4.3.7 Starting the Restriction Editor
Clicking on the option „Starting Restriction Editor“ on the FILE menu causes the "Feeder Editor: Losplanung“
to be opened. In this editor it is possible to define for the individual lot files given allocations, restrictions, bindings
and exclusions (see chapt. 9).
Procedure:
● Click on a lot file.
● On the SERVICES menu click on the Starting Restriction Editor option.
„Feeder Editor: Losplanung“ opens.
11.4.3.8 Checking for Producibility
Following the optimization run, a producibility check can be carried out for a lot file or for individual jobs. The
producibility check takes into account gantry dependencies and vibration times of the feeders. The results are
therefore more accurate than with optimization.
Procedure:
● Click on a lot file or a job.
● On the SERVICES menu click on the Perform producibility check option.
A producibility check is then performed.