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User Manual Line Computer UNIX 11 Production Tools / Optimization Software Vers ion 502.xx 10/2000 Issue 11.4 Optimization Dialog 339 I t I I - Clustering ON/OFF This bu tton is used t o toggle the "cluste ring"…
11 Production Tools / Optimization User Manual Line Computer UNIX
11.4 Optimization Dialog Software Version 502.xx 10/2000 Issue
338
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- Remove components that are not required from fixed set-up
This parameter is used to define that components that are not contained in the PCB types to be opti-
mized will be removed from the fixed setup and made available for reallocation by the setup optimiza-
tion. New components can only be added to the fixed setup if the button "Allocate components to empty
feeder compartments" is activated in addition (see above).
Dynamic changeover procedures are supported. If a setup family was formed by, let’s say, five pro-
ducts, such setup family can be used as a fixed setup for a new setup optimization run if two products
were removed and two new products were added. No changeover procedures need therefore be per-
formed for the three remaining products, and hence no tests have to be performed. This results in
considerable time savings. The two new products will be optimally integrated into the ’stripped down’
fixed setup thus allowing for a continuous dynamic setup optimization process.
- WPC/MTC
- Load WPC/MTC 100%
In a setup, not all levels of the Wafflepack Changer need necessarily to be occupied by
components.
This parameter permits you to specify that Optimization is to assign components to all empty trays as
well, i.e. in accordance with their usage frequency rate across all PCBs of a lot file.
- Towers of MTC to be set up identically
This parameter allows you to specify that Optimization is to set up the two towers of the matrix-tray
changer identically.
- SETUP CLUSTERING
- Clustering According to the Sequence or Mean Value Method: Setup clustering can be carried out
by any one of two different methods which can be selected by activating the appropriate icon.
Sequence:
Starting situation: A number of jobs exist that are to be produced only once and in any sequence desi-
red.
Optimization: Optimization forms setup clusters and suggests a production sequence. If this
sequence is observed, the jobs can be produced keeping set-up changeover time to a minimum.
Mean value:
Starting situation: A number of jobs exist that are to be produced over and over again at varying and
unforeseeable instances.
Optimization: Optimization forms setup clusters resulting in minimum changeover times for any setup
changeover procedure desired.
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 502.xx 10/2000 Issue 11.4 Optimization Dialog
339
I
t I I
- Clustering ON/OFF
This button is used to toggle the "clustering" option on and off. If the option is deactivated, optimization
cannot form set-up families, but only create a setup, or abort, if applicable, the optimization process
and issue an error message.
- CHANGEOVER TIMES
Set-Up Optimization requires a basis for the calculation of the changeover times. The parameters listed in
the following can be set to specify how much time is required for setup changeover operations.
- Basic set-up changeover time [sec]: The basic set-up change-over time refers to the time that elap-
ses between the last placement from the predecessor setup and the first placement of the follow-up
setup. The actual setup changeover times are not included in the calculation.
The default setting is 600 sec.
- Table changeover time [sec]: Estimated time required for the removal and installation of a component
changeover table. While the placement process continues, the feeders are prepared, away from the line,
on a second changeover table. The changeover table is then exchanged completely during the chan-
geover procedure. The default setting is 180 sec (= 90 sec for taking down + 90 sec for setting up).
To be able to use this parameter, a feeder part must be defined as component changeover table in the
Configuration Editor (see
chapt. 12).
- Feeder changeover time [sec]: Estimated time required for the removal and installation of a feeder
on a fixed component table. The feeders are prepared outside the line with the placement process
continuing. They must be changed over individually; this is why the time required for the setup
changeover increases with the number of machine components to be changed over. The default set-
ting is 60 sec (= 30 sec for taking down + 30 sec for setting up).
- Changeover time for MTC [sec]: This is the estimated time required for the removal or installation of
the waffle-pack tray carrier from or into the matrix-tray changer. The waffle-pack trays are prepared for
the placement operation and placed into the waffle-pack tray carriers away from the line.
The default setting is 7200 sec (= 3600 sec for taking down + 3600 sec for setting up).
- Filling up changeover tables
This parameter permits you to specify that on the changeover tables components from the initial setup
are to be included in the follow-up setup, even if they are not required. The setup changeover effort
can thus be kept to a minimum.
Note: This parameter only affects Clustering.
Meaning of the buttons
- Reset
This button is used to reset the standard values to the default values. They are deleted when so doing.
- OK
This button is used to accept the modified values.
- Cancel
This button is used to discard the modified values and to restore the previous state.
11 Production Tools / Optimization User Manual Line Computer UNIX
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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.