Programming feeder Setup

I guess you want to try a permanent feeder setup. This is possible if the total number of feeders needed to cover all of the different products can be installed on your machines. Then just use the same setup data for all your product. Each program will use only the appropriate feeders. You will never need to do feeder setup changeover. If one machine is not enough to hold all the feeders, then just add more machines :-)

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Yes, you need to use "dedicated feeders" and only make changes when you run out of a part. It may even be better if you could convince the stock room and keep stock for those parts right on your line. The environment has to be proper for that though, dry cabinets etc. You can also do the same thing with tray parts, if you're using any.

The next stage is "off-line setup". While your operators are running the line, few other people has to prepare the setup for the next product. You need to have good planning at least to know what product to run next, and also enough feeders. You can always do this for the feeders you have, and if you need to buy feeders, you can buy the cheap types and live with the reel replacement of the expensive feeders.

Further, if you have two machines, you can keep the first machine cycle-time a bit higher than the second. And place a buffer after the first machine or use the conveyor to save boards while the second machine setup is being done. Once the second machine is ready, it would catch-up with the first one considering the difference in cycle times.

Depending on the cycle-time ratio of the two machines, your first machine may be finished placing parts for that lot while the second machine is trying to place the boards, so you can start setting up the first machine for the next board type again. Screen printer can also be done in advance, using the buffer concept. Please be careful though, if you run 20 boards and anything unexpected happens to one board, you will not have your screen printer to print another board, or your first machine to place the parts again.

So, these techniques are a bit risky, you're the one to decide whether they will improve your line efficiency or not.

Hope these help.

Erhan

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Look into the Multi-Job Line Balancer. You select a group of products that you want to run and WHAM-Oh! A setup sheet is created that tells you what you need to move once you run out of room or a part number is no longer needed. Contact Fuji America for details.

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