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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 effe ct of t he lot size ca n b…
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.
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 501.xx 01/99 Issue 11.3 Setup Optimization
11 - 11
● 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.
Setup of Waffle-Pack Changer
Waffle-pack magazines (WTs) require waffle-pack tray carriers (WTCs).
The allocation of WPTs to WPCs is performed with the aid of the Feeder Editor.
WTCs are automatically included in the setup created by the Setup Optimization (just as modules are set up if,
for example, a 4.5 mm or 9.5mm linear feeder is required).
NOTE
Empty WTCs set up at a configured station or as part of a fixed setup are not
assigned waffle-pack trays
by Setup Optimization.
For each WTC a maximum of one waffle-pack tray is set up.
(The assignment of several waffle-pack trays to a particular WTC can be specified in the fixed setup).
Manually loaded WTCs are automatically included in the setup.
Feeders are only placed underneath a manual WTC of the HS-180 if a fixed setup has been preset in which
feeders are to be set up underneath the WTC.
Head camera and CRDL Tester are not set up automatically
NOTE
Head camera and CRDL Tester must have been configured at the station by means of the Configuration
Editor prior
to the use of the Setup Optimization (see chapt. 12) if components are present that have to be
centered optically or require CRDL measuring.