An integrated approach to line assignment problem in electronic card production considering process flow

Yıl 2024, , 2409 - 2422, 20.05.2024

Ömer Faruk Ünal , Şeyda Serdarasan

https://doi.org/10.17341/gazimmfd.1340123

Öz

The efficient operation of electronic cards, which are used as a subcomponent in many products such as telephones, televisions, computers, automobiles and smart devices, depends on appropriate design, production and quality. High product variety in production processes, production capacity constraints and setup times in model changes can result in non-value-added intermediate operations and lead times, resulting in inefficiency.

This study proposes an effective approach to the line assignment problem for electronic board production addressing efficiency increase and cost reduction. The resulting production plan, which will provide the highest production amount of electronic cards in different assembly and testing lines, considers different characteristics of electronic cards (eg. bill of materials, common component use, number of components, demand, operation times and process flow). The PCB line assignment problem, which is in the NP-hard problem class, is solved by clustering analysis and a 0-1 mixed integer mathematical model. The results of the model were analyzed with a simulation model that models the operation of the production line.

In the application made with real data, 22% improvement was achieved in the production amount compared to the current situation by using the proposed approach. The proposed approach can be applied to the scheduling of an electronic board manufacturer with multiple surface mount technology (SMT) assembly lines, multiple process flows, and multiple testing stations.

Anahtar Kelimeler

PCB assembly, PCB line assignment problem, Electronic card, two step clustering

Elektronik kart üretiminde hat atama problemi için süreç akışını dikkate alan bütünleşik bir yaklaşım

Öz

Telefon, televizyon, bilgisayar, otomobil ve akıllı cihazlar gibi birçok üründe bir alt bileşen olarak kullanılan elektronik kartların verimli bir şekilde çalışmaları uygun tasarım, üretim ve kaliteye bağlıdır. Üretim süreçlerinde yüksek ürün çeşitliliği, üretim kapasite kısıtları ve model değişikliklerindeki hazırlık süreleri, katma değersiz ara operasyon ve sürelerle sonuçlanarak verimsizliğe neden olabilir.

Bu çalışma, elektronik kart üretimi için hat atama problemlerini ele alarak verimlilik artışı ve maliyet düşürme amaçlı yenilikçi ve etkili yaklaşımlar önermektedir. Elektronik kartların farklı üretim ve test hatlarında en büyük üretim miktarını sağlayacak üretim planı farklı kriterler (örn. ürün ağacı, ortak bileşen kullanımı, bileşen adetleri, talepler, operasyon süreleri ve süreç akışında uğrayacağı istasyonlar ve sıralar) göz önünde bulundurularak belirlenmektedir. NP-zor problemi sınıfında yer alan PCB hat atama problemi, kümeleme analizi ve 0-1 karma tamsayılı matematiksel modelle çözülmektedir. Modelin sonuçları üretim hattının işleyişini modelleyen simülasyon modeli ile analiz edilmiştir.

Gerçek verilerle yapılan uygulamada, önerilen yaklaşım kullanılarak üretim miktarında mevcut duruma oranla %22 oranında iyileşme sağlanmıştır. Önerilen yaklaşım, birden çok yüzey montaj teknolojisi (SMT) özelliğine sahip otomatik dizgi hattı, birden çok süreç akışı ve birden çok test ayar istasyonuna sahip bir elektronik kart üreticisinin çizelgelemesi için uygulanabilir.

Anahtar Kelimeler

hat atama problemi, elektronik kart, PCB montaj, iki adımlı kümeleme, simülasyon

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