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User Manual Line Computer UNIX 11 Production Tools / Optimization Software Version 501.xx 01/99 Issue 11.3 Setup Optimization 11 - 9 11.3.3.2 Fixed Se tup It is po ssible for the op erator to predete rmine a fixe d setup…
11 Production Tools / Optimization User Manual Line Computer UNIX
11.3 Setup Optimization Software Version 501.xx 01/99 Issue
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 --> Initial 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
- Placement Position editor in the PCB EditorDefining a placement sequence by allocating
placement positions to different placement
levels (see chapt. 8)
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 501.xx 01/99 Issue 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).
● Empty compartments/feeders may be removed from the fixed setup and be reallocated by the setup
optimization.
This setting is made in the standard parameters (see section 11.4.3.1).
● Components that are not required may be removed from the fixed setup and be made available for
reallocation by the setup optimization.
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 of the initial setup that are no longer required will
only be taken down if other components are to be set up in their place. How many of the components - remaining
allocated to the tracks exactly as they were - will be taken over 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.
11 Production Tools / Optimization User Manual Line Computer UNIX
11.3 Setup Optimization Software Version 501.xx 01/99 Issue
11 - 10
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
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.