This paper considers a material constrained component scheduling problem during the high speed surface mount manufacturing stage in printed circuit board (PCB) assembly, where each piece of board contains an even number of identical PCBs. To accomplish the production, material requirements must be predetermined and incorporated as restraints into the scheduling problem, which has the objective of minimizing production completion time (makespan). A solution procedure is developed based on the following strategies: 1) Each machine is responsible for the same PCBs of each piece, 2) Components of the same types may use one or more feeder locations, 3) Component types are clustered based on their suitable placement speeds, 4) A heuristic using a bottom-up approach is applied to determine the component placement sequence and the feeder location assignment for all machines. Velocity estimate functions of the turret, XY table, and feeder carriage were derived based on empirical data. An experiment using Fuji CP732E machines was conducted on two real life instances. Experimental results indicate that our method performs 32.96% and 10.60% better than the Fuji-CP software for the two instances, in terms of the makespan per piece of board.
M. Ayob and G. Kendall, “A Survey of Surface Mount Device Placement Machine Optimisation: Machine Classification,” European Journal of Operational Research, Vol. 186, No. 3, 2008, pp. 893-914.
Y. Crama, O. E. Flippo, J. V. D. Klundert and F. C. R. Spieksma, “The Component Retrieval Problem in Printed Circuit Board Assembly,” International Journal of Flexible Manufacturing Systems, Vol. 8, No. 4, 1996, pp. 287-312. doi:10.1007/BF00170016
Y. Crama, O. E. Flippo, J. V. D. Klundert and F. C. R. Spieksma, “The Assembly of Printed Circuit Boards: A Case with Multiple Machines and Multiple Board Types,” European Journal of Operational Research, Vol. 98, No. 3, 1997, pp. 457-472.
K. Ohno, Z. Jin and S. E. Elmaghraby, “An Optimal Assembly Mode of Multi-Type Printed Circuit Boards,” Computers and Industrial Engineering, Vol. 36, No. 2, 1999, pp. 451-471. doi:10.1016/S0360-8352(99)00142-4
C. Klomp, J. V. D Klundert, F. C. R. Spieksma and S. Voogt, “The Feeder Rack Assignment Problem in PCB Assembly: A Case Study,” International Journal of Production Research, Vol. 64, No. 1, 2000, pp. 399-407.
K. P. Ellis, F. J. Vittes and J. E. Kobza, “Optimizing the Performance of a Surface Mount Placement Machine,” IEEE Transactions on Electronics Packaging Manufacturing, Vol. 24, No. 3, 2001, pp. 160-170.
H. Wu and P. Ji, “A Genetic Algorithm Approach to Optimizing Component Placement and Retrieval Sequence for Chip Shooter Machines,” International Journal of Advanced Manufacturing Technology, Vol. 28, No. 5, 2006, pp. 556-560. doi:10.1007/s00170-004-2390-2
C. C. Chyu and W. S. Chang, “A Genetic-Based Algorithm for the Operational Sequence of a High Speed Chip Placement Machine,” International Journal of Advanced Manufacturing Technology, Vol. 36, No. 9-10, 2008, pp. 918-926. doi:10.1007/s00170-006-0918-3
R. Kumar and Z. Luo, “Optimizing the Operation Sequence of a Chip Placement Machine Using TSP Model,” IEEE Transactions on Electronics Packaging Manufacturing, Vol. 26, No. 1, 2003, pp. 14-21.
G. Moon, “Efficient Operation Methods for a Component Placement Machine Using the Patterns on Printed Circuit Boards,” International Journal of Production Research, Vol. 48, No. 10, 2010, pp. 3015-3028.
T. Knuutila, M. Hirvikorpi, M. Johnsson and O. Nevalainen, “Grouping PCB Assembly Jobs with Feeders of Several Types,” International Journal of Flexible Manufacturing Systems, Vol. 16, No. 2, 2004, pp. 151- 167. doi:10.1023/B:FLEX.0000044838.12637.0e
R. Narayanaswami and V. Iyengar, “Setup Reduction in Printed Circuit Board Assembly by Efficient Sequencing,” International Journal of Advanced Manufacturing Technology, Vol. 26, 2005, pp. 276-284.
K. Salonen, J. Smed, M. Johnsson and O. Nevalainen, “Grouping and Sequencing PCB Assembly Jobs with Minimum Feeder Setups,” Robotics and Computer-Inte- grated Manufacturing, Vol. 22, No. 4, 2006, pp. 297-305.
M. J. Rosenblatt and H. L. Lee, “The Effects of Work-In- Process Inventory Costs on the Design and Scheduling of Assembly Lines with Low Throughput and High Component Costs,” IIE Transactions, Vol. 28, No. 5, 1996, pp. 405-414. doi:10.1080/07408179608966287
K. P. Ellis, J. E. Kobza and F. J. Vittes, “Development of a Placement Time Estimator Function for a Turret Style Surface Mount Placement Machine,” Robotics and Computer-Integrated Manufacturing, Vol. 18, No. 3-4, 2002, pp. 241-254. doi:10.1016/S0736-5845(02)00015-7