Modeling the machine configuration and line-balancing problem of a PCB assembly line with modular placement machines

Rong, Aiying; Tóth, Attila; Nevalainen, Olli; Knuutila, Timo; Lahdelma, Risto

doi:10.1007/s00170-010-2920-z

Cited by 15 publications

(10 citation statements)

References 29 publications

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“…The problem formulation of MCLB-M is a generalisation of the MCBL for the single PCB type case (Rong et al 2011). Now, the production plan includes b PCB types and a different component types in total.…”

Section: Machine Configuration and (Work) Load Balancing For Multiple Products (Mclb-m)mentioning

confidence: 99%

“…As shown in Section 3, an exact mathematical formulation for the MCLB-M problem is not easy to provide and an exact way of solving it is not known. Furthermore, in the article by Rong et al (2011) it was found that their integer programme for an easier problem was hard to solve and advanced techniques for traversing the solution space are required. In addition, the solution time of the model was very large for bigger problem instances.…”

Section: Mathematical Modelmentioning

confidence: 99%

“…Although the mixed-model case is examined in the present study, the configuration problem for modular placement machines also appears in the single model machine set-up strategy; but in the latter without any machine set-ups between the jobs (Toth, Knuutila, and Nevalainen 2010;Rong et al 2011;Guo et al 2012). The same problem also appears in different forms in other branches of industry; see Boysen, Fliedner, and Scholl (2008) for some example application areas.…”

Section: Introductionmentioning

confidence: 99%

“…The two sub-problems (the configuring and balancing of the MCLB-M) are closely interconnected. In Rong et al (2011), a joint mathematical model was presented for the single job case (MCLB) and solved in an optimal way for small instances. The approach is, however, too time-consuming for real-world problem sizes.…”

Section: Introductionmentioning

confidence: 99%

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Machine configuration and workload balancing of modular placement machines in multi-product PCB assembly

Tóth

Knuutila

Nevalainen

2018

International Journal of Computer Integrated Manufacturing

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A popular gantry-type placement machine includes several interconnected, autonomously operating component placement modules and the machine was designed so as to able to use different kinds of placement heads and vacuum nozzles in the modules, which can be easily changed. Although this increases the flexibility of the production line, the reconfiguration phases of the modules may be unproductive and one should keep them to a minimum. In addition, the production times can be shortened by balancing the workloads of the machine modules. Here, a two-step optimisation method for the machine reconfiguration and workload balancing in the case of multiple Printed Circuit Borad (PCB) batches of different sizes and PCB types is presented. The objective is to minimise the total production time, and keep the machine configuration the same for all batches. The proposed algorithm is iterative and it applies integer programming for the workload balancing along with an evolutionary algorithm that searches for the best machine configuration. In experiments, for single PCB types the proposed algorithm obtained optimal or near optimal solutions. For multiple PCB types the solutions favour the PCB types that have a bigger production time due to greater batch sizes, but the total production time is still close to optimal.

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Section: Machine Configuration and (Work) Load Balancing For Multiple Products (Mclb-m)mentioning

confidence: 99%

Section: Mathematical Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Machine configuration and workload balancing of modular placement machines in multi-product PCB assembly

Tóth

Knuutila

Nevalainen

2018

International Journal of Computer Integrated Manufacturing

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“…The PCB assembly design and control problems of the tactical level depend on the numbers of PCB types to be produced and on the machines in use (Johnsson 1999). Higher levels of the problem hierarchy include strategic planning of the whole PCB assembly plant (Rogers and Warrington 2004), reconfiguration problem of the modular placement machines (Grunow, Günther, and Schleusener 2003;Toth, Knuutila, and Nevalainen 2010;Rong 2011), job grouping (Knuutila et al 2004;Yilmaz et al 2007) and production line balancing problem (Lapierre, Debargis, and Soumis 2000;Emet et al 2010). Higher levels of the problem hierarchy include strategic planning of the whole PCB assembly plant (Rogers and Warrington 2004), reconfiguration problem of the modular placement machines (Grunow, Günther, and Schleusener 2003;Toth, Knuutila, and Nevalainen 2010;Rong 2011), job grouping (Knuutila et al 2004;Yilmaz et al 2007) and production line balancing problem (Lapierre, Debargis, and Soumis 2000;Emet et al 2010).…”

Section: Introductionmentioning

confidence: 99%

Estimating the production time of a PCB assembly job without solving the optimised machine control

Vainio

Pahikkala

Johnsson³

et al. 2014

International Journal of Computer Integrated Manufacturing

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Production planning and control of the printed circuit board (PCB) assembly includes several decisions dealing with, for example, grouping of PCB jobs, allocation of PCB batches to machine lines, sequencing of batches and load balancing of lines. The production time of a PCB job for a given placement machine is a key factor in this context and it must be quickly and accurately estimated, possibly millions of times in a single planning task, to avoid erroneous decisions. The commonly used nominal tact time-based estimators are very rough and the machine simulators too slow. Therefore, the purpose of this study is to give better machine-specific estimators that avoid the construction the actual machine control program. Two new estimators are proposed for gantry machines, one based on the information given by the manufacturer about the operations of the placement head, and the other on the regularised least-squares regression method trained with a set of PCB placement jobs. In practical evaluation with 95 PCB jobs, the mean absolute percentage error of the first and second methods are 3.75% and 6.52%, respectively, while that of the tact time-based approach is more than 17%. This indicates a great potential of the proposed methods as production time estimators.

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An integrated allocation method for the PCB assembly line balancing problem with nozzle changes

Guo

Takahashi

Morikawa

et al. 2011

Int J Adv Manuf Technol

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Modeling the machine configuration and line-balancing problem of a PCB assembly line with modular placement machines

Cited by 15 publications

References 29 publications

Machine configuration and workload balancing of modular placement machines in multi-product PCB assembly

Machine configuration and workload balancing of modular placement machines in multi-product PCB assembly

Estimating the production time of a PCB assembly job without solving the optimised machine control

An integrated allocation method for the PCB assembly line balancing problem with nozzle changes

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