備料限制下印刷電路板高速機生產策略之個案分析

Material Constrained Production Planning Procedure in Printed Circuit Board Assembly: A Case Study with Single Chip Shooting Machine

杜澤儒(Tse-Ju Tu)

指導教授 ： 徐旭昇

元智大學/工程學院/工業工程與管理學系/碩士(2007年)

摘要

在電子製造業裡,表面黏著技術（Surface mount technology）用於自動化生產組裝 PCB 板（Printed circuit boards），一直是一個非常熱烈的討論議題，因此本研究將探討表面黏著技術之元件置放順序問題以縮短整體生產 PCB 板所需之完工時間。本研究針對富士 CP732 高速機進行問題探討，並提出以下幾種考慮因子策略：（1）考慮每次生產PCB時所需的備料限制，因此允許料槽分割，（2）將不同的元件依照它們的屬性及置件速度進行分群，（3）使用最鄰近法則（Nearest-neighborhood-rule）定義元件置放順序，（4）使用由下而上法則（Bottom-up-rule）定義置料槽順序。本研究依照現場機器量測並使用回歸方程式測發展出 XY-Table 移動公式、置料槽移動公式以及旋轉盤轉動公式等，利用這些公式，可以模擬出本研究所演算出來的 PCB 版完工時間。最後本研究將演算出之結果套用於案例公司之實際機器上生產，其表現效果比案例公司目前生產策略較佳。

關鍵字

表面黏著技術, 元件置放順序, 備料限制, 料槽分割, 最鄰近法則, 由下而上法則

並列摘要

In modern printed circuit board (PCB) assembly, surface mount technology (SMT) is widely used to populate boards with electronic components. In this thesis, we focus our study on improving the manufacturing efficiency of component placement jobs performed by the high speed turret style ship shooting machine. Such component placement sequence is a complex problem. In particular, we investigate a situation where one Fuji-CP732 machine is used to manufacture a board, which may contain multiple identical PCBs, with the objective of minimizing the assembly time per board subject to material supply constraints. Decisions in this problem involve: (a) the assignment of component placement job to each machine, (b) the allocation of component types to the feeder slots of each machine, and (c) the specified order of components to be placed for each machine.
A solution procedure is developed based on the following strategies: (1) Assigning each machine to work on the same PCBs of each board piece, (2) Clustering the component types based on their suitable placement speeds and then processing the groups one by one with speed from high to low, (3) Applying a bottom up approach with the Nearest Neighbor search to determine the component placement sequence and the feeder location assignment for the machine.
Velocity estimate functions of turret, PCB table, and feeder carriage were derived using connecting points method based on empirical data. Two experiments are conducted in two real-life instances: (1) One board type has each piece containing two identical PCBs, one on the upper part and the other on the lower part, and (2) The other board type has each piece involving four identical PCBs with locations arranged in series. Our experimental results indicate that the proposed method will make significantly more monthly production revenue than the Fuji-CP software in these two specific situations.

並列關鍵字

Printed circuit boards assembly, surface mount technology, nearest neighbor search, component placement sequence, feeder location assignment.

參考文獻

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