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11 Production Tools / Optimization User Manual Line Computer UNIX 11.4 Optimization Dialog Software Version 5 02.xx 10 /2000 Issue 340 I t I I 1 1.4.3.2 E xamples of Par a mete r Settings The par ameter set tings for Set…
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 502.xx 10/2000 Issue 11.4 Optimization Dialog
339
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- 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
11.4 Optimization Dialog Software Version 502.xx 10/2000 Issue
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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.
User Manual Line Computer UNIX 11 Production Tools / Optimization
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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.