Optimization Manual

Original Instructions

OTM-FLX-2.5E
It is necessary to comply with the terms of the
license agreement prior to using Fuji Flexa.
Fuji Flexa

Optimization Manual

OTM-FLX-2.5E

FUJI MACHINE MFG. CO., LTD.

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or in part, be reproduced by any means (electronic, mechanical or otherwise), or reused in any way, with-
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Fuji Machine Mfg. Co., Ltd. accepts no responsibility for situations that may arise due to any of the follow-
ing:
• The use of third party parts.
• The use of non-genuine Fuji parts.
• Incorrect settings made by the customer.
• Improper use of Fuji equipment.

The RFID system is a product of Cogiscan.

Notice
Fuji Machine Mfg. Co., Ltd. reserves the right to change the content of this manual without notice.
Every effort has been made to ensure that this manual is correct in every detail. However, please contact
Fuji in the unlikely event that errors or omissions are detected.
Fuji Machine Mfg. Co., Ltd. accepts no liability whatsoever for damages that may arise as a result of this
manual, with the exception of problems that originate in our products.
OTM-FLX-2.5E Contents

Contents
1. Optimizing Jobs and Balancing Lines.................. 1
1.1 Applications Categorized by Function.............. 2
1.1.1 Optimizing a single job............................................ 2
1.1.2 Optimizing multiple jobs.......................................... 2
1.2 Explanation of Functions.................................. 3
1.2.1 Assigning parts in a job to machines ...................... 3
1.2.2 Optimizing a single job............................................ 3
1.2.3 Optimizing multiple jobs.......................................... 5
2. Line Balancing ..................................................... 9
2.1 Line Balance in Job Builder.............................. 9
2.2 Line Balancer ................................................. 10
2.2.1 Important points .................................................... 10
2.2.2 Using Line Balancer.............................................. 11
3. Multi Job Line Balancers................................... 15
3.1 Multi Job Line Balancer.................................. 16
3.1.1 Using Multi Job Line Balancer .............................. 17
3.1.2 Reading the optimization report............................ 26
3.2 NXT Multi Job Line Balancer.......................... 28
3.2.1 Using NXT Multi Job Line Balancer ...................... 29
3.2.2 Reading the optimization report............................ 43
3.3 NXT AB Mode Multi Job Line Balancer.......... 46
3.3.1 Using NXT AB Mode Multi Job Optimizer............. 47
3.3.2 Reading the optimization report............................ 60
3.4 AIMEX Multi Job Line Balancer...................... 63
3.4.1 Using AIMEX Multi Job Line Balancer .................. 64
3.4.2 Reading the optimization report............................ 76
3.5 AIMEX AB Mode Multi Job Line Balancer...... 78
3.5.1 Using AIMEX AB Mode Multi Job Optimizer......... 79
3.5.2 Reading the optimization report............................ 92
3.6 AIM Multi Job Line Balancer .......................... 95
3.6.1 Using AIM Multi Job Line Balancer....................... 96

Fuji Flexa Optimization Manual i

 Contents OTM-FLX-2.5E

3.6.2 Reading the optimization report ......................... 105

4. Optimizing ........................................................ 107
4.1 Optimize in Job Builder ................................ 107
4.2 NXT Multi Machine Optimizer ...................... 109
4.2.1 Using NXT Multi Machine Optimizer .................. 111
4.3 NXT Dual Production Optimizer ................... 122
4.3.1 Using NXT Dual Production Optimizer............... 122
4.4 NXT Triple Production Optimizer ................. 128
4.4.1 Using NXT Triple Production Optimizer ............. 128
4.5 AIMEX Multi Machine Optimizer .................. 134
4.5.1 Using AIMEX Multi Machine Optimizer .............. 136
4.6 AIMEX Dual Production Optimizer ............... 145
4.6.1 Using AIMEX Dual Production Optimizer........... 145
4.7 XPF Multi Machine Optimizer ...................... 151
4.7.1 How to use XPF Multi Machine Optimizer.......... 152
5. Multi Line Multi Job Line Balancer.................... 157
5.1 Required Items............................................. 157
5.1.1 Operating system ............................................... 157
5.1.2 Hardware............................................................ 157
5.1.3 Supported machines .......................................... 157
5.2 Using Multi Line Multi Job Line Balancer ..... 158
5.3 Reports ........................................................ 172
5.3.1 Overall report ..................................................... 172
5.3.2 Detailed Report .................................................. 174
6. Multi Machine Multi Job Line Balancer............. 177
6.1 Supported machines .................................... 177
6.2 Using Multi Machine Multi Job Line
Balancer ....................................................... 178
6.3 Reading the optimization report ................... 190

ii Fuji Flexa Optimization Manual

OTM-FLX-2.5E Introduction

Introduction
This manual explains how to perform line balancing and optimization of jobs created in Job
Builder.

Line balancing ensures that parts are allocated appropriately to each machine in the line.
Optimizing ensures that the machine order and feeder allocation are arranged as
efficiently as possible.

Refer to the “Fuji Flexa User Manual” for details on how to edit jobs and how to transmit
jobs that have been optimized to the machine.

Notation conventions used in this manual

The notation conventions employed in this manual are described below.

General notation

Notation sample Explanation

[File] menu Menu names and commands are enclosed in square

brackets [ ].

[Open Job] window Window and dialog box names which appear in the title
bar are enclosed in square brackets [ ].

[OK] The names of toolbar buttons and command buttons that

appear inside a window or dialog box are enclosed in
square brackets [ ].

[Enter] key Key names are enclosed in square brackets [ ].

Mouse-related notation

Notation Explanation

Click Press and quickly release the left mouse button.

Double-click Click the left mouse button twice in rapid succession

Right-click Press and quickly release the right mouse button.

Drag Move icons, dialog boxes and windows or adjust windows

by clicking and shifting the object in question while holding
down the left mouse button.

Drop Release the left mouse button once an object has been
dragged to the desired position.

Fuji Flexa Optimization Manual iii

Introduction OTM-FLX-2.5E

MEMO:

iv Fuji Flexa Optimization Manual

OTM-FLX-2.5E 1. Optimizing Jobs and Balancing Lines

1. Optimizing Jobs and Balancing

Lines
Application functions
The following table shows what functions each optimizer application supports.

Optimizing application Assigns parts to Optimizes

machines placement
sequences

Line Balance in Job Builder Yes No

Line Balancer Yes Yes

Multi Job Line Balancer Yes Yes

Multi Line Multi Job Line Balancer Yes Yes

NXT Multi Job Line Balancer No* Yes

NXT AB Mode Multi Job Line Balancer No* Yes

AIMEX Multi Job Line Balancer No* Yes

AIMEX AB Mode Multi Job Line Balancer No* Yes

AIM Multi Job Line Balancer No* Yes

Optimize in Job Builder No Yes

NXT Multi Machine Optimizer No* Yes

NXT Dual Production Optimizer No Yes

NXT Triple Production Optimizer No Yes

AIMEX Multi Machine Optimizer No* Yes

AIMEX Dual Production Optimizer No* Yes

XPF Multi Machine Optimizer No* Yes

*When there are multiple NXT, AIMEX, AIM, XPF “machines” in a line, parts already
assigned to a machine can be reassigned.

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1. Optimizing Jobs and Balancing Lines OTM-FLX-2.5E

1.1 Applications Categorized by Function

This section lists the different types of optimizer by the functions they perform.

1.1.1 Optimizing a single job

Assign parts to machines
• Line Balance in Job Builder

• Line Balancer

Optimize (placing sequences for each machine, feeder allocation)

• Optimize in Job Builder

• NXT Multi Machine Optimizer

• NXT Dual Production Optimizer

Note: Optimizes two jobs being produced in lane 1 and lane 2.

• NXT Triple Production Optimizer

Note: Optimizes three jobs being produced in lane 1, lane 2 and lane 3.

• AIMEX Multi Machine Optimizer

• AIMEX Dual Production Optimizer

Note: Optimizes two jobs being produced in lane 1 and lane 2.

• XPF Multi Machine Optimizer

1.1.2 Optimizing multiple jobs

• Multi Job Line Balancer

• NXT Multi Job Line Balancer

• NXT AB Mode Multi Job Line Balancer

• AIMEX Multi Job Line Balancer

• AIM AB Mode Multi Job Line Balancer

• AIM Multi Job Line Balancer

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OTM-FLX-2.5E 1. Optimizing Jobs and Balancing Lines

1.2 Explanation of Functions

This section explains the functions of each optimizer application and gives the relative
advantages and disadvantages of each type.

1.2.1 Assigning parts in a job to machines

Line Balance in Job Builder
Parts are assigned to machines in the line so that a the cycle times are roughly balanced.

Advantage
• Processing speed is fast.

Disadvantages
• Getting a good line balance is difficult because cycle times are calculated
roughly.

• Each machine must be optimized after processing because feeders are not
allocated and the part placement order is not optimized.

Line Balancer
Machine types: NXT-series, AIMEX, AIM, XPF-series, XP-series, CP-6/7/8-series,
QP-242, QP-341

Parts are allocated to machines to balance the cycle time of each machine in the line while
optimizing the part placement sequence of each machine.

Advantages
• A better line balance can be attained because parts are assigned while
optimizing the part placement sequence of each machine.

• Machines do not have to be individually optimized because feeders are

allocated and the part placement sequence is optimized.

Disadvantage
• Processing takes a long time.

1.2.2 Optimizing a single job

Optimize in Job Builder
Optimizes the placement sequence of assigned parts, allocates feeders and can optimize
the feeder allocation of each machine.

NXT Multi Machine Optimizer

Machine types: NXT-series

When there are multiple NXT “machines” in one line (a machine can be made of multiple
bases), parts assigned to NXT machines are reassigned and the placement order and
feeder allocation of all NXT modules are optimized. Parts assigned to other machine types
are not affected by this process.

A simple optimization of the heads for each module can be performed.

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1. Optimizing Jobs and Balancing Lines OTM-FLX-2.5E

(1) Differences compared to Line Balance in Job Builder and Line Balancer
a. Part assignment
When there are NXT machines and other machine types in a single line, Line
Balance in Job Builder and Line Balancer can assign parts to each machine.
However, NXT Multi Machine Optimizer does not assign parts to machines, but can
only reassign parts previously assigned to NXT machines in a single line.

b. Performance
The processing speed is faster than Line Balancer.

When there are multiple NXT “machines” (a machine can be made of multiple bases)
in one line, NXT Multi Machine Optimizer balances the cycle times, optimizes the
placement sequence, allocates feeders and can optimize feeder allocation better
than Line Balance in Job Builder.

(2) Support for multi-lane production

NXT Multi Machine Optimizer does not support production of different jobs in multiple
lanes.
NXT Dual Production Optimizer or NXT Triple Production Optimizer must be used to
optimize jobs for multi-lane production.

NXT Dual Production Optimizer

Machine types: NXT-series

When the NXT is performing dual lane production with different jobs in lane 1 and lane 2,
the optimal placement order of parts assigned to the NXT and the optimal feeder allocation
for the jobs is created.

NXT Triple Production Optimizer

Machine types: NXT-series

When the NXT is performing triple lane production with different jobs in lane 1, lane 2 and
lane 3, the optimal placement order of parts assigned to the NXT and the optimal feeder
allocation for the jobs is created.

AIMEX Multi Machine Optimizer

Machine types: AIMEX

When there are multiple AIMEX “machines” in one line (multiple AIMEXs can be connected
to make one “machine”), parts assigned to AIMEX machines are reassigned and the
placement order and feeder allocation of all AIMEX modules are optimized. Parts assigned
to other machine types are not affected by this process.

A simple optimization of the heads for each module can be performed.

(1) Differences compared to Line Balance in Job Builder and Line Balancer
a. Part Assignment
When there are AIMEX machines and other machine types in a single line, line
balance in Job Builder and Line Balancer can assign parts to each machine.
However, AIMEX Multi Machine Optimizer does not assign parts to machines, but
can only reassign parts previously assigned to AIMEX “machines” in a single line.

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OTM-FLX-2.5E 1. Optimizing Jobs and Balancing Lines

b. Performance
When there are multiple AIMEX “machines” (multiple AIMEXs connected together)
in one line, AIMEX Multi Machine Optimizer balances the cycle times and optimizes
the placement sequence and feeder allocation better than Line Balance in Job
Builder.

The processing speed is faster than Line Balancer.

(2) Support for multi-lane production

AIMEX Multi Machine Optimizer does not support production of different jobs in multiple
lanes.

AIMEX Dual Production Optimizer

Machine types: AIMEX

When the AIMEX is performing dual lane production with different jobs in lane 1 and lane
2, the optimal placement order of parts assigned to the AIMEX and the optimal feeder
allocation for the jobs is created.

XPF Multi Machine Optimizer

Machine types: XPF

When there are multiple XPF “machines” in one line (multiple XPFs can be connected to
make one “machine”), parts assigned to XPF machines are reassigned and the placement
order and feeder allocation of all XPF modules are optimized. Parts assigned to other
machine types are not affected by this process.

A simple optimization of the heads for each module can be performed.

(1) Differences compared to Line Balance in Job Builder and Line Balancer
a. Part Assignment
When there are XPF machines and other machine types in a single line, line balance
in Job Builder and Line Balancer can assign parts to each machine. However, XPF
Multi Machine Optimizer does not assign parts to machines, but can only reassign
parts previously assigned to XPF “machines” in a single line.

b. Performance
When there are multiple XPF “machines” (multiple XPFs connected together) in one
line, XPF Multi Machine Optimizer balances the cycle times and optimizes the
placement sequence and feeder allocation better than Line Balance in Job Builder.

The processing speed is faster than Line Balancer.

(2) Support for multi-lane production

XPF Multi Machine Optimizer does not support production of different jobs in multiple
lanes.

1.2.3 Optimizing multiple jobs

Multi Job Line Balancer
Machine types: NXT-series, AIMEX, AIM, XPF-series, XP-series, CP-6/7/8-series,
QP-242, QP-341

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1. Optimizing Jobs and Balancing Lines OTM-FLX-2.5E

Multi Job Line Balancer assigns parts in multiple jobs to machine in a line. It also creates
a feeder allocation that reduces feeder changeover.

Recipes are not created by Multi Job Line Balancer. After completing Multi Job Line
Balancer the [Generate Recipes/Reports] command in Job Builder must be used for the
machines in each job.
Note: The [Generate Recipes/Reports] command can be selected from the [Tools] menu in Job
Builder. Refer to the "Job Builder" section in the Fuji Flexa User Manual for details.

NXT Multi Job Line Balancer

Machine types: NXT-series

Creates a feeder allocation that reduces feeder changeover for NXT machines in multiple
jobs.

This application is exclusively for NXT machines. Information regarding the assignment of
parts to the NXT must be created before using this application.

If a multi-base NXT machine is defined as a single line, like NXT Multi Machine Optimizer,
parts are reassigned and the line is balanced.

This application supports dual lane production with different jobs in lane 1 and 2.
Note: It does not support triple lane production with different jobs in lane 1, lane 2 and lane 3.
Caution: When there are NXT machines and other machine types in a line, NXT machines in multiple
jobs can be optimized because part assignments to NXT and other machine types are not
changed. However, NXT machines and other machine types cannot be optimized
simultaneously.

NXT AB Mode Multi Job Line Balancer

Machine types: NXT-series

This is an optimization application for multiple jobs on NXT lines that prevents production
stoppages and allows for optimum changeover by dividing the feeder pallet into two
sections, so that changeover can be performed on one section, while production continues
using the other section.

This application is exclusively for NXT machines. Information regarding the assignment of
parts to the NXT must be created before using this application.

If a multi-base NXT machine is defined as a single line, like NXT Multi Machine Optimizer,
parts are reassigned and the line is balanced.

This application supports dual lane production with different jobs in lane 1 and 2.
Note: It does not support triple lane production with different jobs in lane 1, lane 2 and lane 3.
Caution: When there are NXT machines and other machine types in a line, NXT machines in multiple
jobs can be optimized because part assignments to NXT and other machine types are not
changed. However, NXT machines and other machine types cannot be optimized
simultaneously.

AIMEX Multi Job Line Balancer

Machine types: AIMEX

Creates a feeder allocation that reduces feeder changeover for AIMEX machines in multiple
jobs.

This application is exclusively for AIMEX machines. Information regarding the assignment
of parts to the AIMEX must be created before using this application.

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OTM-FLX-2.5E 1. Optimizing Jobs and Balancing Lines

Caution: When there are AIMEX machines and other machine types in a line, AIMEX machines in
multiple jobs can be optimized because part assignments to AIMEX and other machine
types are not changed. However, AIMEX machines and other machine types cannot be
optimized simultaneously.

AIMEX AB Mode Multi Job Line Balancer

Machine types: AIMEX

This is an optimization application for multiple jobs on AIMEX lines that prevents production
stoppages and allows for optimum changeover by dividing the feeder pallet into two
sections, so that changeover can be performed on one section, while production continues
using the other section.

This application is exclusively for AIMEX machines. Information regarding the assignment
of parts to the AIMEX must be created before using this application.

If a multi-base AIMEX machine is defined as a single line, like AIMEX Multi Machine
Optimizer, parts are reassigned and the line is balanced.

This application supports dual lane production with different jobs in lane 1 and 2.
Caution: When there are AIMEX machines and other machine types in a line, AIMEX machines in
multiple jobs can be optimized because part assignments to AIMEX and other machine
types are not changed. However, AIMEX machines and other machine types cannot be
optimized simultaneously.

AIM Multi Job Line Balancer

Machine types: AIM

Creates a feeder allocation that reduces feeder changeover for AIM machines in multiple
jobs.

This application is exclusively for AIM machines. Information regarding the assignment of
parts to the AIM must be created before using this application.
Caution: When there are AIM machines and other machine types in a line, AIM machines in multiple
jobs can be optimized because part assignments to AIM and other machine types are not
changed. However, AIM machines and other machine types cannot be optimized
simultaneously.

Fuji Flexa Optimization Manual 7

1. Optimizing Jobs and Balancing Lines OTM-FLX-2.5E

MEMO:

8 Fuji Flexa Optimization Manual

OTM-FLX-2.5E 2. Line Balancing

2. Line Balancing
Line balancing is performed to balance the workload of each machine as much as possible.

This section explains how to perform line balancing in Fuji Flexa.

2.1 Line Balance in Job Builder

Note: Line Balance currently cannot split a part between two or more machines when there are a
large number of the same parts being placed. When you want to allocate multiple parts with
the same part number to multiple machines, perform the [Line Balance] command
according to the instructions given here and then refer to the "Assigning parts" section of
the "Job Builder" chapter in the Fuji Flexa User Manual in order to re-allocate some of the
parts.

1. Select [Line Balance] from the [Tools] menu to display the [Line Balancer Options] dialog
box.

05OTM-0001E

2. Select one of the options from the [Feeder allocation] group. Explanations of each option
are given below.

Do not use current All parts are assigned to each machine without
feeder allocation considering any parts already specified in the [Feeder
Setup] tab of the machine configuration.

Use current feeder Parts are assigned to machines while considering any
allocation parts already present in the [Feeder Setup] tab of the
machine configuration.

3. Click [Start] to display the [Line Balancer] dialog box and perform line balancing.

05OTM-0002E

Note: Click [Stop] to stop the line balancing.

4. When line balancing has been completed, click [Close] to close the dialog box.
5. If there are any errors, click [Error Details] to view the errors. Check the content of the
error, then click [Close] to exit the dialog box.

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2. Line Balancing OTM-FLX-2.5E

Correct the contents of the job in Job Builder, and perform line balancing again.
Note: The modified contents are not reflected in recipes immediately (for machines that require
recipes). They are reflected when the job for the machine that will place those parts is
created. Parts that display in the [Edit Skipped Feeder] window are not supported by Line
Balancer. After performing line balancing, allocate those parts in the [Edit Skipped Feeder]
window (using the move command).

2.2 Line Balancer

05OTM-0003E

2.2.1 Important points

For jobs for which Line Balancer is used, it is necessary to perform line balancing
beforehand in Job Builder to ensure that jobs are free of errors.
Refer to section "Line Balance in Job Builder" in this manual and the "Line Balancing"
section in the "Job Builder" chapter of the Fuji Flexa User Manual.

Line Balancer supports the following machine types.

Machine type Model

NXT-series NXT, NXT-2

AIMEX AIMEX

AIM AIM

XPF-series XPF-L, XPF-S, XPF-W

XP-series XP-141E, XP-142E, XP-143E,

XP-241E, XP-242E, XP-243E,
XP-341E

CP-8 series CP-842E, CP-842ME

CP-7 series CP-732E, CP-733E, CP-742E, CP-742ME,

CP-743E, CP-743E-CS, CP-743ME

CP-6 series CP-642E, CP-643E

QP-series QP-242E, QP-341E-DM, QP-341E-MM

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OTM-FLX-2.5E 2. Line Balancing

2.2.2 Using Line Balancer

1. Click the [Optimizer] tab in Director, and then click the [Line Balancer] icon.

05OTM-0004E

The start screen of the Line Balancer wizard is displayed.

05OTM-0003E

Note: Line Balancer can also be started by clicking the [Start] button and selecting [Programs] -
[Fuji Flexa] - [Optimizer] - [Line Balancer].
Note: Line Balancer can also be started by selecting [Line Balance] from the [Tools] menu in Job
Builder.

2. Click [Next] at the first step of the Line Balancer wizard to display STEP 1.

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2. Line Balancing OTM-FLX-2.5E

05OTM-0005E

3. Click the button in the [Job] group box to display the job list dialog box.

05OTM-0006

4. Select the name of the job to be used in the job list dialog box and then click [OK]. The
job list dialog box is closed, the selected job is displayed in the [Job] group box, and the
job line configuration is displayed in the [Line configuration] group box.

05OTM-0007E

5. Click [Next] to display STEP 2.

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OTM-FLX-2.5E 2. Line Balancing

05OTM-0008E

6. Select any appropriate options in the [Optional Settings] group box.

7. Click [Next] to display STEP 3 and perform line balancing. When processing begins, the
status is displayed at the top.

05OTM-0009E

Note: A confirmation dialog box is displayed if [Cancel] is clicked during processing. By clicking
[Yes], processing is aborted and STEP 3 is closed. By clicking [No], processing is
continued.

8. When processing is complete, perform either of the following depending on the content
of the status message.

a. If the message states that "Line balancing and optimization were successful."
Click [Save] followed by [Exit] to save the processing content and complete the line
balancing procedure. To exit line balancing without saving the processing content,
click [Exit] and then click [Yes] in the displayed dialog box. STEP 3 is then closed.

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2. Line Balancing OTM-FLX-2.5E

05OTM-0010E

b. If the message states "Unable to line balance and optimize."

Click [Error Log], check the content of the error in the displayed dialog box, then click
[Close] to close the dialog box. STEP 3 is then closed. Correct any errors using Job
Builder and then run Line Balancer again.

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OTM-FLX-2.5E 3. Multi Job Line Balancers

3. Multi Job Line Balancers

Multi Job Line Balancer is an application to create feeder allocations that will result in the
least changeover work when jobs are changed.

The following types of Multi Job Line Balancer are available for lines that consist of certain
machines.

Multi Job Line Balancer

Use this to line balance jobs for lines that consist of machines other than NXT-series and
AIM-series machines.

NXT Multi Job Line Balancer

Use this to line balance jobs for lines that consist of only NXT-series machines, or lines that
consist of NXT-series and XPF-series machines.

NXT AB Mode* Multi Job Line Balancer

Use this to line balance jobs for lines that consist of only NXT-series machines when you
require support for AB mode production.

*AB Mode
This is when one section of the feeder pallet has parts set for the current production and
the other section of the feeder pallet has parts set for the next production.

AIMEX Multi Job Line Balancer

Use this to line balance jobs for lines that consist of only AIMEX machines.

AIMEX AB Mode Multi Job Line Balancer

Use this tool to line balance jobs for lines that consist of only AIMEX machines when you
require support for AB mode production.

AIM Multi Job Line Balancer

Use this to line balance jobs for lines that consist of only AIM machines.

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3. Multi Job Line Balancers OTM-FLX-2.5E

3.1 Multi Job Line Balancer

Multi Job Line Balancer is software used to create a common feeder setup and optimize the
placement order of parts in each job for machines in the same line used to produce multiple
jobs.

05OTM-0011E

The following preparations are required in order to use this application.

• This uses part related data on the part data server, not from specific jobs. It will
therefore be necessary to first export part related data from the jobs if it does not
exist on the part data server.
• It is necessary to use the same line in all of the jobs. Import the same line to all
jobs if necessary.

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OTM-FLX-2.5E 3. Multi Job Line Balancers

3.1.1 Using Multi Job Line Balancer

1. Click the [Multi Job Line Balancer] tab in Director and then click the [Multi Job Line
Balancer] icon.

05OTM-0012E

The start screen of the Multi Job Line Balancer wizard is displayed.

05OTM-0011E

Note: Multi Job Line Balancer can also be started by clicking the [Start] button and selecting
[Programs] - [Fuji Flexa] - [Multi Job LineBalancer] - [MultiJob LineBalancer].

2. Click [Next] at the first step of the Multi Job Line Balancer wizard to display STEP 1.

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3. Multi Job Line Balancers OTM-FLX-2.5E

05OTM-0013E

3. Click [Add] to display a job selection dialog box.

05OTM-0014

4. Select the jobs to be used at the job selection dialog box.

Note: To select multiple jobs, click the jobs while holding down the [CTRL] key.

5. After completing job selection at the job selection dialog box, click [OK].
The job selection dialog box is then closed and the [Select panel side] dialog box is
displayed.

05OTM-0015Ea

6. In the [Select panel side] dialog box, select the panel side for the selected jobs from
[Top], [Bottom] or [Top / Bottom], and then click [OK].
The [Select panel side] dialog box is then closed, and the selected jobs are added to the
list.

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OTM-FLX-2.5E 3. Multi Job Line Balancers

05OTM-0016E

Setting Description
Name Displays the name of the job.
Revision Displays the revision of the job.
Face Displays the side of the panel for production for the job.
Top: The top side is to be produced.
Bottom: The bottom side is to be produced.
Top/Bottom: Both the top and bottom are to be produced.
Group Displays the group name for the job.
Production Quantity Displays the quantity of panels to be produced.

7. Repeat steps 3 to 6 if adding more jobs to the list.

Note: To delete a job from the list, select it and then click [Delete]. To delete all jobs from the list,
click [Clear].

8. When finished adding jobs, click [Next] to display STEP 2.

05OTM-0017E

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3. Multi Job Line Balancers OTM-FLX-2.5E

9. Click the button in the [Job used for line or feeder setup] group box to display a job
list dialog box.

05OTM-0018

10.Select the name of the job to use for the line and feeder setup in the job list dialog box,
then click [OK]. The job list dialog box is then closed, and the selected job is displayed
in the [Job used for line or feeder setup] group box.

11.Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job used for line or feeder setup] group box.

12.Select the following option in the [Job used for line or feeder setup] group box if required.

Setting Description
Acquire part data Normally, part data is acquired from the part data server.
from this job However, if this check box is selected, the part data from the job
instead of the selected in [Job used for line or feeder setup] is used.
server. Note: When this setting is selected, it is necessary for the
specified job to have all of the part data from all of the
jobs selected in step 1.

13.Select the appropriate option in the [Settings] group box.

Setting Description
Group jobs for A common feeder allocation for multiple jobs is created and the
batch jobs are grouped. There are times when multiple groups are
changeover. possible. In this case, changeover between groups occurs but
the feeder allocation is not common between groups.
Reduce feeder A common feeder allocation for multiple jobs is created and the
changeover jobs are grouped. There are times when multiple groups are
times. possible. In this case, changeover between groups occurs.
However, the feeder allocation of the previous group is
considered. As a result, a feeder allocation is created that
reduces the changeover of the feeder allocation as much as
possible. Compared to [Group jobs for batch changeover], the
number of feeder changeovers is reduced. However, it is
difficult to balance the cycle time.
Calculate The program automatically calculates whether it is more
changeover beneficial to prioritize changeover or cycle time before
method from optimization.
production count When this option is selected, select an optimization level (Low,
and cycle time: Mid, High).

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OTM-FLX-2.5E 3. Multi Job Line Balancers

14.Select the appropriate option in the [Allocate Parts to Machine] group box.

15.Click [Next] to display STEP 3.

05OTM-0019E

16.If you wish to change the production order, select the job and use the [Up] and [Down]
buttons to change the order. To optimize the production order, click [Optimize]. A dialog
box displays with an optimization option choice.

05OTM-0020E

Option Description
Optimize jobs in order to This optimizes the order to minimize the amount
reduce feeder change of changeover.
times
Order by production The jobs are ordered based on the quantity of
quantity panels to be produced for each job.

17.Select the desired optimization option in the dialog box and click [OK]. The dialog box
is then closed, and the production order is automatically changed.

18.Click [Next] to display STEP 4.

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3. Multi Job Line Balancers OTM-FLX-2.5E

05OTM-0021Eb

19.If optimizing the nozzle setup on XP-141/142 machines, select the [Optimize XP-141,
XP-142 nozzle setup] check box.
Note: Select the same check box if optimizing the nozzle setup on the XP-143.

20.If a job produced on a line containing an XP-241/242/341 is selected, select the

appropriate option at the [XP-241, XP-242, XP-341 feeder allocation conitions] group
box.
Note: Make the same selections if a job produced on a line containing the XP-243 is selected.

21.Enter suitable values for each parameter in the [Changeover parameters] group box.

22.Click [Next] to display STEP 5.

05OTM-0022E

23.To display a cycle time graph after running Multi Job Line Balancer, select the [Display
cycle time graph] check box.

24.If required, set the operating rate of each machine in the line at the [Machine operation
rate] group box.

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25.If machines exist for which the number of times changeover is performed is to be
reduced, select the check box for the relevant machine(s) at the [Specify machines that
should avoid changeover whenever possible] group box.

26.Click [Next] to display STEP 6.

05OTM-0023E

27.Select the machine from the drop-down list at the top.

28.Select the feeders that can be used for the machine selected above in the [Feeder
Available] tab.

29.Select the nozzles that can be used for the machine selected above at the [Nozzle
Available] tab.

30.To perform processing for multiple machines, repeat steps 28 and 29 again for each
machine.

31.Click [Next] to display STEP 7.

05OTM-0024E

32.If all the current settings are correct, click [Next] to display STEP 8 and perform line
balancing.

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3. Multi Job Line Balancers OTM-FLX-2.5E

05OTM-0025E

Note: When processing begins, the status is displayed in the [Status] group box. Furthermore, if
the [Display cycle time graph] check box was selected at STEP 5, the [Cycle Time] dialog
box is displayed.

33.When processing is complete, perform either of the following depending on the content
of the message in the [Status] group box.

a. If the message states “Line balance successful”

If the [Cycle Time] dialog box is displayed, the cycle time for each job is shown.
Details of the optimization processing result are output to the report.

05OTM-0026E

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05OTM-0027

• Click [Display Report] to refer to the report. Refer to section " 3.1.2 Reading the
optimization report " for a view of the report.
Click [Save Report] to save the report.
• Click [Save] followed by [Exit] to save the processing content and complete the
line balancing procedure. Alternatively, to exit line balancing without saving the
processing content, click [Exit] and then click [OK] in the confirmation box that
displays.
STEP 8 is then closed, along with the [Cycle Time] dialog box if it is displayed.
b. If the message states “Repeating optimization until cancelled...”
The user is responsible for deciding when to terminate the procedure.
• If satisfied with the cycle time displayed in the graph and wishing to save the
processing content and exit line balancing, click [Cancel], [OK], [Save] and
[Finish] in this order.
• Continue processing if not satisfied with the cycle time. It should be noted,
however, that the cycle time may not improve even when continuing. To exit
without saving the processing content, click [Cancel], [OK], [Finish] and [Yes] in
this order.
The STEP 8 screen is then closed, as is the [Cycle Time] dialog box if displayed.

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3.1.2 Reading the optimization report

The optimization results from Multi Job Line Balancer are displayed in the following report.

(a)

(b)

(c)

(d)

(e)

(f)
(g)

(h)

05OTM-0029E

(a) Title
(b) Report header

Item Description
Date Displays the date when optimization processing was completed
without any errors.
Time Displays the time when optimization processing was completed
without any errors.
User Name Displays the Fuji Flexa logged on user name when optimization
processing was performed.

(c) Timing report

This section of the report displays the optimized cycle time and changeover time for the jobs
in the order they are to be produced.
Item Description
Job Name Displays the name of the job.
Cycle Time (sec.) Displays the cycle time for one panel.
Production Time (min.) This displays the production time which is "Cycle Time" x
"number of panels to produce".
Change Over Time (min.) Displays the time for changeover.

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(d) Group name

Displays the group name for the jobs. The "0" part of the name changes for each group
because this section is broken down into groups.

(e) Job name

The names of jobs in the same group are displayed in a list. It is possible to perform
production between the jobs within this list without changing the feeder allocation.

Format: "Job Name" / "Panel Side" ("Top", "Bottom")

(f) Model name

Displays the model name of the machine in the jobs. When there are multiple machines in
the line, a nozzle setup report and feeder setup report are displayed for each machine
model.

(g) Nozzle setup report

Item Description
No Displays the nozzle station socket number.
Name Displays the name of the nozzle.
Spec Name Displays the specification name for the nozzle.
Diameter Displays the diameter of the nozzle.
Size X Displays the X-direction size of the nozzle.
Size Y Displays the Y-direction size of the nozzle.
Lighting Displays the kind of the lighting for the nozzles.

(h) Feeder Setup Report

Item Description
Position Displays the stage number and the slot number of the feeder.
Result Compares the feeder allocation to the feeder allocation for the [Job
used for line or feeder setup] job (from STEP 2) and indicates whether
feeders need to be added, removed, or exchanged.
Add: Add the feeder.
Delete: Remove the feeder.
Change: Exchange the feeder.
Part Number Displays the part number for the part.
Part Comment Displays the part comment for the part.
Type Displays the feeder type.
Width [mm] Displays the width of the reel.
Qty Displays the placing quantity per panel for that position.

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3. Multi Job Line Balancers OTM-FLX-2.5E

3.2 NXT Multi Job Line Balancer

NXT Multi Job Line Balancer is a tool to create feeder allocations that will result in the least
changeover work and to optimize the placement order. This software is specially designed
for use with NXT machines.

NXT Multi Job Line Balancer software is an option and a license is required in order to use
it.

05OTM-0030Ea

The following has to be completed/fulfilled before using this application.

• Copy any part data used in the jobs to the part data server because the part data
that is used by the optimizer is taken from the part data server.
• For all of the jobs for which processing is to be performed by the NXT Multi Job
Line Balancer, have them all use the same line that includes at least one NXT
machine type.
• Because the NXT Multi Job Line Balancer cannot change the assignments of
the parts in the jobs, be sure to have all of the necessary parts assigned in each
job beforehand.

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3.2.1 Using NXT Multi Job Line Balancer

1. Click the [Multi Job Line Balancer] tab in Director and then click the [NXT Multi Job Line
Balancer] icon.

05OTM-0031E

The start screen of NXT Multi Job Line Balancer wizard is displayed.

05OTM-0030Ea

Note: Multi Job Line Balancer can also be started by clicking the [Start] button and selecting
[Programs] - [Fuji Flexa] - [MultiJob Line Balancer] - [NXT MultiJob LineBalancer].

2. Select the [Support XPF] check box if there are XPF machines in the lines and you wish
to create feeder allocations and optimize the placement order for those machines as
well.

3. Click [Next] in the NXT Multi Job Line Balancer wizard to display STEP 1.

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3. Multi Job Line Balancers OTM-FLX-2.5E

05OTM-0032Ea

4. Click [Add] to display a job selection dialog box.

05OTM-0033a

5. Select the jobs to be used in the job selection dialog box.

Note: To select multiple jobs, click the jobs while holding down the [CTRL] key.

6. After completing job selection at the job selection dialog box, click [OK]. The job
selection dialog box is then closed and the [Select panel side] dialog box is displayed.

05OTM-0015Ea

7. In the [Select panel side] dialog box, select the panel side for the selected jobs from
[Top], [Bottom] or [Top / Bottom], and then click [OK]. The [Select panel side] dialog box
is then closed, and the selected jobs are added to the list.

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05OTM-0034Ea

Setting Description
Name Displays the name of the job.
Revision Displays the revision of the job.
Face Displays the side of the panel for production for the job.
Top: The top side is to be produced.
Bottom: The bottom side is to be produced.
Top/Bottom: Both the top and bottom are to be produced.
Group Displays the group name for the job.
Production Quantity Displays the quantity of panels to be produced.
Prioritizing Displays the side that is to be produced first (top or bottom).
Production When optimizing the production order in STEP 4, this setting
is checked and the production order is determined.
Top: The top side is to be produced before the bottom.
Bottom: The bottom side is to be produced before the top.
Either: A specific order for top or bottom is not specified.

8. Repeat steps 4 to 7 if adding more jobs to the list.

Note: To delete a job from the list, select it and then click [Delete]. To delete all jobs from the list,
click [Clear].

9. When changing the side for which the job is performed, the production quantity, or the
production priority order, select and right click the applicable job and select the
appropriate option from the menu.

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05OTM-0227E

･Selecting the [Enter the production quantity] will display the [Production Quantity]
dialog box.

Enter the production quantity and click [OK].

10.When setting the commonality calculation method, click the [...] button in the upper right
of the screen. The [Commonality Calculation Settings] dialog box displays.

05OTM-0229E

Note: The communality is calculated for the job selected in order to know the level of communality
at which the the parts used in the job are used between jobs.

Select the appropriate option, enter the value as according to requirements, and then
click [OK].

11.When finished adding jobs, click [Next] to display STEP 2.

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05OTM-0035Eb

12.Click the button in the [Job used for line or feeder setup] group box to display a job
list dialog box.

05OTM-0036a

13.Select the name of the job to use as the line and feeder setup at the job list dialog box,
and then click [OK]. The job list dialog box is then closed, and the selected job is
displayed in the [Job used for line or feeder setup] group box.

14.Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job used for line or feeder setup] group box.

15.Select the following option in the [Job used for line or feeder setup] group box if required.

Setting Description
Acquire part data Normally, part data is acquired from the part data server.
from this job However, if this check box is selected, the part data from the job
instead of the selected in [Job used for line or feeder setup] is used.
server. Caution: When this setting is selected, it is necessary for the
specified job to have all of the part data from all of the
jobs selected in STEP 1.

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3. Multi Job Line Balancers OTM-FLX-2.5E

16.Select the appropriate option in the [Feeder allocation settings] group box.

Setting Description

Consider the The feeder allocation of the [Job used for line or feeder
allocation of all setup] is used for optimization.
feeders

Consider the Only feeders with a Reserved and Fixed status in the feeder
allocation of allocation of the [Job used for line or feeder setup] are
Reserved and Fixed considered during optimization.The allocation of feeders
feeders only with a Variable status is not considered.

17.To optimize without changing the machine configuration specified in the job, select the
[Use the Machine Configuration as is in each job] check box.
Caution: In order to use this function, a separate license is required in addition to the license for NXT
Multi Job Line Balancer.

18.Select the appropriate option in the [Settings] group box.

Setting Description
Group jobs for A common feeder allocation for multiple jobs is created and the
batch jobs are grouped. There are times when multiple groups are
changeover. possible. In this case, changeover between groups occurs but
the feeder allocation is not common between groups.
Reduce feeder A common feeder allocation for multiple jobs is created and the
changeover jobs are grouped. There are times when multiple groups are
times. possible. In this case, changeover between groups occurs.
However, the feeder allocation of the previous group is
considered. As a result, a feeder allocation is created that
reduces the changeover of the feeder allocation as much as
possible. Compared to [Group jobs for batch changeover], the
number of feeder changeovers is reduced. However, it is
difficult to balance the cycle time.
Calculate The program automatically calculates whether it is more
changeover beneficial to prioritize changeover or cycle time before
method from optimization.
production count When this option is selected, select an optimization level (Low,
and cycle time: Mid, High).

19.Click [Next] to display STEP 3.

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05OTM-0037Eb

20.Enter suitable values for each parameter in the [Changeover parameters] group box.

Setting Description
Feeder Specify the time required for one person to change one
feeder.
Nozzle Specify the time required for one person to change one
nozzle.
Stage unit Specify the time required for one person to change the
stage.
Head Specify the time required for one person to change a head.
Nozzle station Specify the time required for one person to change the
nozzle station.

Note: The [Stage unit], [Head], and [Nozzle station] fields are available if the [Use the Machine
Configuration as is in each job] check box was selected in step 2.

21.Enter appropriate values in the [Changeover parameters] group.

Setting Description
Persons Specify the number of people performing changeover at the
same time.
Caution: If "1" is specified, calculation will be performed with
one changeover person for current production and
one changeover person for the next production.

22.In the [Specify modules that should avoid changeover whenever possible] box, select
the modules for which changeover should be avoided whenever possible. This option
is enabled only if the following two settings have been made in the previous step.

• Feeder allocation setting:

Consider the allocation of Reserved and Fixed feeders only.
• Setting:
Reduce feeder changeover times.

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3. Multi Job Line Balancers OTM-FLX-2.5E

23.Click [Next] to display STEP 4.

05OTM-0038Ea

24.Change the production order if necessary. The production order can be changed
automatically or manually.

Automatic method
a. Click the [Optimize] button if you wish to optimize the production order. A dialog box
displays with an optimization option choice.

05OTM-0020E

Option Description
Optimize jobs in order to This optimizes the order to minimize the amount of
reduce feeder change times changeover.
Order by production quantity The jobs are ordered based on the quantity of
panels to be produced for each job.

b. Select the desired optimization option in the dialog box and then click [OK]. The
dialog box closes and the production order is changed automatically.

Manual method
a. Select jobs from the list and use the [Up] and [Down] buttons to move them.
b. Specify the panel transport method for each job by right-clicking the desired job and
selecting the appropriate option from the menu.

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05OTM-0039Ea

Panel conveyance Description

menu items
Dual Optimize / Lane1 [Dual Optimize / Lane1] and [Dual Optimize /
Lane2] must be specified as a set. When these are
Dual Optimize / Lane2 selected, the movement time when changing lanes
and nozzle changeover time is considered.
Single Lane Specify this when producing a job at a single lane.
Dual Lane / Lane1 Specify this when producing a job at lane 1 of a
dual lane machine.
Dual Lane / Lane2 Specify this when producing a job at lane 2 of a
dual lane machine.
Specify changeover Specify groups for which changeover is performed.
group
When a group is selected the optimum nozzles are
set for each group.
Note: [Dual Optimize / Lane1] and [Dual Optimize / Lane2] are unavailable if the [Use the Machine
Configuration as is in each job] check box was selected in step 2.

25.When performing changeover for group units, follow the procedure below to specify the
group settings.

a. Select the [Specify changeover group] check box.

b. Select and right-click the applicable job, then select [Specify changeover group] from
the menu.

c. Enter the changeover group number in the displayed [Specify changeover group]
dialog box and then click [OK].

26.Click [Next] to display STEP 5.

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05OTM-0040Eb

27.Specify the settings you want to use.

Setting Description
Display cycle time If this option is selected, then a cycle time graph is displayed
graph during processing.
Allocate parts with If this is selected, parts with many placements will be set in
excessive multiple feeders and placed on multiple modules if possible.
sequences to
multiple modules
Divide parts on fixed When [Allocate parts with excessive sequences to multiple
feeder modules] is selected, you can specify whether to reallocate
parts on fixed feeders.
If this option is selected, parts on fixed feeders can be
allocated to other modules to reduce cycle time.
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup. (The job allocation specified in
step 2 is used.)
Use the same nozzle This specifies whether or not to use a shared nozzle allocation
allocation for all jobs for all jobs.
This is available when [Divide parts on fixed feeder] is
selected. However, this is not available if the [Use the
Machine Configuration as is in each job] check box was
selected in step 2.
Prioritize Select in cases where feeders are to be exchanged with
changeover for group device parts as priority when changeovers occur.
group device parts

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28.Specify whether or not reel holders are on feeders by selecting the type from the [Used
feeder type] drop-down list.

• If set to [Reel holder], the optimizer positions feeders in the feeder setup
considering that the feeders have reel holders.
• If set to [Reel holder-E], the optimizer positions feeders in the feeder setup
considering that the feeders do not have reel holders and that a bucket type
feeder pallet is used.
29.Select the [Optimize Auto-Tool to use] check box and select [Processing time limit] from
the drop-down list when optimizing auto-tools.
Note: Processing time limit:
Specify the processing time limit for one round of optimization for the auto-tools
to be used.

30.For jobs using paired module production, specify the desired settings in the [Paired
module production] group box as necessary.

Setting Description

Optimize panel This specifies whether or not the panel stopping position is
stopping position optimized for paired module production. This is only for M3-
2 modules when they are performing paired module
production.

Optimize for single This specifies whether or not paired module production is
module production used for panels between 250 and 305 in length. This setting
has no bearing for panels outside of this range.
If this is not selected and the panel size is within the range,
the M3-2 modules are automatically paired for paired
production. If this is selected and the panel size is within the
range, the M3-2 modules are not paired.
For panels smaller than the range, M3-2 modules are never
paired. For panels larger than the range, M3-2 modules are
always paired.

Allocate parts in the This specifies whether or not to allocate parts that are in the
interference area to head interference area during paired module production to
M6 modules M6-2 modules if possible. By selecting this option, head
waiting time during paired module production is reduced.
However, more parts are assigned to the M6-2 module.

Dividing parts is If the check box is selected, dividing parts is possible when
possible when arranged in M3 paired modules even for parts for which
arranged in M3 paired dividing is not permitted.
modules even for
parts for which
dividing is not
permitted.

31.Click [Next] to display STEP 6.

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3. Multi Job Line Balancers OTM-FLX-2.5E

05OTM-0041Ea

32.Select the feeders that can be used in the [Feeder Available] tab.

33.Select the nozzles that can be used in the [Nozzle Available] tab.

34.Click [Next] to display STEP 7.

05OTM-0042Ea

35.If all the current settings are correct, click [Next] to display STEP 8 and perform line
balancing.

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05OTM-0043Ea

Note: When processing begins, the status is displayed in the [Status] group box. Furthermore, if
the [Display cycle time graph] check box was selected at STEP 5, the [Cycle Time] dialog
box is displayed.

36.When processing is complete, perform one of the following depending on the content of
the message in the [Status] group box.

a. If the message states “Line balance successful”

If the [Cycle Time] dialog box is displayed, the cycle time for each job is shown.
Details of the optimization processing result are output to the report.

05OTM-0044Ea

• Click [Display Report] to refer to the report. Refer to section " 3.2.2 Reading the
optimization report " for a view of the report.
Click [Save Report] to save the report.
• Click [Save] followed by [Exit] to save the processing content and complete the
line balancing procedure. Alternatively, to exit line balancing without saving the
processing content, click [Exit] and then click [OK] in the confirmation box that
displays.
STEP 8 is then closed.

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3. Multi Job Line Balancers OTM-FLX-2.5E

b. If the message states “Repeating optimization until cancelled...”

The user is responsible for deciding when to terminate the procedure.

• If satisfied with the cycle time displayed in the graph and wishing to save the
processing content and exit line balancing, click [Cancel], [OK], [Save] and
[Finish] in this order.
• Continue processing if not satisfied with the cycle time. It should be noted,
however, that the cycle time may not improve even when continuing. To exit
without saving the processing content, click [Cancel], [OK], [Finish] and [Yes] in
this order.
STEP 8 is then closed.
c. If the message states "Unable to balance the line"

• Click [Error Log] to display the errors from the message group box in a text editor
such as Notepad. Checks the contents of any errors.
Click [Exit] after the checking the content of errors.
STEP 8 is then closed.
Correct any errors using Job Builder and then run NXT Multi Job Line Balancer
again.

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3.2.2 Reading the optimization report

The optimization results from NXT Multi Job Line Balancer are displayed in the following
report.

(a)

(b)

(c)

(d)

(e)

(f)
(g)

(h)

(i)

(j)

(k)

05OTM-0048Ea

(a) Title
(b) Report header

Item Meaning
Date Displays the date when optimization processing was
completed without any errors.
Time Displays the time when optimization processing was
completed without any errors.
User Name Displays the Fuji Flexa logged on user name when
optimization processing was performed.

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3. Multi Job Line Balancers OTM-FLX-2.5E

(c) Timing report

This section of the report displays the optimized cycle time and changeover time for the jobs
in the order they are to be produced.

Item Description
Job Name Displays the name of the job.
Cycle Time (sec.) Displays the cycle time for one panel.
Production Time (min.) This displays the production time which is "Cycle Time" x
"number of panels to produce".
Change Over Time Displays the time for changeover.
(min.)

(d) Group name

Displays the group name for the jobs. The "0" part of the name changes for each group
because this section is broken into groups.

(e) Job name

The names of jobs in the same group are displayed in a list. It is possible to perform
production between the jobs within this list without changing the feeder allocation.

Format: "Job Name" / "Panel Side" ("Top", "Bottom")

(f) Model name

Displays the model name of the machine in the jobs. When there are multiple machines in
the line, a nozzle setup report and feeder setup report are displayed for each machine
model.

(g) Stage type report

Item Description
No Displays the module number.
Result Compares the stage to the stage for the [Job used for line or
feeder setup] job (from STEP2) and indicates whether the stage
needs to be exchanged.
Change: Exchange the stage.
Name Displays the stage name

(h) Nozzle changer report

Item Description
No Displays the module number.
Result Compares the stage to the stage for the [Job used for line or
feeder setup] job (from STEP2) and indicates whether the stage
needs to be exchanged.
Change: Exchange the stage.
Name Displays the nozzle changer name.

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(i) Head type report

Item Description
No Displays the module number.
Result Compares with the job specified in step 2 for using as the line/
feeder configuration and displays whether or not to change the
head.
Change: Exchange the stage.
Name Displays the head name.

(j) Nozzle changer setup report

Item Description
No Displays the nozzle station socket number.
Result Compares the nozzle allocation to the nozzle allocation for the
[Job used for line or feeder setup] job (from STEP2) and indicates
whether nozzles need to be added, removed, or exchanged.
Add: Add the nozzle.
Delete: Remove the nozzle.
Change: Exchange the nozzle.
Name Displays the name of the nozzle.
Spec Name Displays the specification name for the nozzle.
Diameter Displays the diameter of the nozzle.
Size X Displays the X-direction size of the nozzle.
Size Y Displays the Y-direction size of the nozzle.
Head Type Displays the specification type for the placing head that can use
that nozzle.
Length Displays the length of the nozzle.

(k) Feeder setup report

Item Description
Position Displays the stage number and the slot number of the feeder.
Result Compares the feeder allocation to the feeder allocation for the
[Job used for line or feeder setup] job (from STEP 2) and
indicates whether feeders need to be added, removed, or
exchanged.
Add: Add the feeder.
Delete: Remove the feeder.
Change: Exchange the feeder.
Part Number Displays the part number for the part.
Part Displays the part comment for the part.
Comment
Type Displays the feeder type.
Width [mm] Displays the width of the reel.
Qty Displays the placing quantity per panel for that position.

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3.3 NXT AB Mode Multi Job Line Balancer

NXT AB Mode Multi Job Line Balancer is an optimization application that prevents
production stoppages and allows for optimum changeover by dividing the feeder pallets into
two sections so that changeover can be performed at one section while production
continues using the other section.

This application builds on the technology of the NXT Multi Job Line Balancer, therefore
optimization is performed with groups that have the same feeder allocation, so changeover
is not needed for jobs within the same group.
Note: If the production amount is small, or depending on the production order, there are cases of
optimization results in which changeover for one side cannot be completed while the other
side is being used in production.

NXT AB Mode Multi Job Line Balancer is an option. In order to use this option, an NXT AB
Mode Multi Job Line Balancer license and an NXT Multi Job Line Balancer license are
required.

05OTM-0049Ea

The following has to be completed/fulfilled before using this application.

• Copy any part data used in the jobs to the part data server because the part data
that is used by the optimizer is taken from the part data server.
• For all of the jobs for which processing is to be performed by the NXT AB Mode
Multi Job Line Balancer, have them all use the same line that includes at least
one NXT machine type.
• Because the NXT AB Mode Multi Job Line Balancer cannot change the
assignments of the parts in the jobs, be sure to have all of the necessary parts
assigned in each job beforehand.
Restrictions
NXT AB Mode Multi Job Line Balancer Manual supports the following stage types.
• DP-20
• DP-45
• TU-M2
• TU-LT
• TU-LTC

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3.3.1 Using NXT AB Mode Multi Job Optimizer

1. Click the [Mode Multi Job Line Balancer] tab in Director and then click the [NXT AB Multi
Job Line Balancer] icon.

05OTM-0050E

The start screen of the NXT AB Mode Multi Job Line Balancer wizard is displayed.

05OTM-0049Ea

Note: AB Mode Multi Job Line Balancer can also be started by clicking the [Start] button and
selecting [Programs] - [Fuji Flexa] - [Multi Job LineBalancer] - [NXT AB Mode MultiJob
LineBalancer].

2. Click [Next] in the NXT AB Mode Multi Job Line Balancer wizard to display STEP 1.

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05OTM-0051Ea

3. Click [Add] to display a job selection dialog box.

05OTM-0052a

4. Select the jobs to be used in the job selection dialog box.

Note: To select multiple jobs, click the jobs while holding down the [CTRL] key.

5. After completing job selection at the job selection dialog box, click [OK]. The job
selection dialog box is then closed and the [Select panel side] dialog box is displayed.

05OTM-0015Ea

6. In the [Select panel side] dialog box, select the panel side for the selected jobs from
[Top], [Bottom] or [Top / Bottom], and then click [OK]. The [Select panel side] dialog box
is then closed, and the selected jobs are added to the list.

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05OTM-0053Ea

Setting Description
Name Displays the name of the job.
Revision Displays the revision of the job.
Face Displays the side of the panel for production for the job.
Top: The top side is to be produced.
Bottom: The bottom side is to be produced.
Top/Bottom: Both the top and bottom are to be produced.
Group Displays the group name for the job.
Production Quantity Displays the quantity of panels to be produced.
Prioritizing Displays the side that is to be produced first (top or bottom).
Production When optimizing the production order in step 4, this setting
is checked and the production order is determined.
Top: The top side is to be produced before the bottom.
Bottom: The bottom side is to be produced before the top.
Either: A specific order for top or bottom is not specified.

7. Repeat steps 3 to 6 above if adding more jobs to the list.

Note: To delete a job from the list, select it and then click [Delete]. To delete all jobs from the list,
click [Clear].

8. When changing the side for which the job is performed, the production quantity, or the
production priority order, select and right click the applicable job and select the
appropriate option from the menu.

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05OTM-0231E

･Selecting the [Enter the production quantity] will display the [Production Quantity]
dialog box.

Enter the production quantity and click [OK].

9. When setting the commonality calculation method, click the [...] button in the upper right
of the screen. The [Commonality Calculation Settings] dialog box displays.

05OTM-0229E

Note: The communality is calculated for the job selected in order to know the level of communality
at which the the parts used in the job are used between jobs.

Select the appropriate option, enter the value as according to requirements, and then
click [OK].

10.When finished adding jobs, click [Next] to display STEP 2.

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05OTM-0054Ea

11.Click the button in the [Job used for line or feeder setup] group box to display a job
list dialog box.

05OTM-0055a

12.Select the name of the job to use as the line and feeder setup at the job list dialog box,
and then click [OK]. The job list dialog box is then closed, and the selected job is
displayed in the [Job used for line or feeder setup] group box.

13.Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job used for line or feeder setup] group box.

14.Select the following option in the [Job used for line or feeder setup] group box if required.

Setting Description
Acquire part data Normally, part data is acquired from the part data server.
from this job However, if this check box is selected, the part data from the job
instead of the selected in [Job used for line or feeder setup] is used.
server. Caution: When this setting is selected, it is necessary for the
specified job to have all of the part data from all of the
jobs selected in STEP 1.

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15.Select the appropriate option in the [Settings] group box.

Setting Description
Group jobs for A common feeder allocation for multiple jobs is created and the
batch jobs are grouped. There are times when multiple groups are
changeover. possible. In this case, changeover between groups occurs but
the feeder allocation is not common between groups.
Reduce feeder A common feeder allocation for multiple jobs is created and the
changeover jobs are grouped. There are times when multiple groups are
times. possible. In this case, changeover between groups occurs.
However, the feeder allocation of the previous group is
considered. As a result, a feeder allocation is created that
reduces the changeover of the feeder allocation as much as
possible. Compared to [Group jobs for batch changeover], the
number of feeder changeovers is reduced. However, it is
difficult to balance the cycle time.

16.Click [Next] to display STEP 3.

05OTM-0056Ea

17.Enter suitable values for each parameter in the [Changeover parameters] group box.

Setting Description
Feeder changeover Specify the time required for one person to change one
(seconds) feeder.
Nozzle changeover Specify the time required for one person to change one
(seconds) nozzle.
Persons Specify the number of people performing changeover at the
same time.
Caution: If "1" is specified, calculation will be performed with
one changeover person for current production and
one changeover person for the next production.

18.Click [Next] to display STEP 4.

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05OTM-0057Ea

19.Change the production order if necessary. The production order can be changed
automatically or manually.

Automatic method
a. Click the [Optimize] button if you wish to optimize the production order. A dialog box
displays with an optimization option choice.

05OTM-0020E

Option Description
Optimize jobs in order to This optimizes the order to minimize the amount of
reduce feeder change times changeover.
Order by production quantity The jobs are ordered based on the quantity of
panels to be produced for each job.

b. Select the desired optimization option in the dialog box and then click [OK]. The
dialog box closes and the production order is changed automatically.

Manual method
a. Select jobs from the list and use the [Up] and [Down] buttons to move them.
b. Specify the panel transport method for each job by right-clicking the desired job and
selecting the appropriate option from the menu.

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05OTM-0058Ea

Panel conveyance Description

menu items
Dual Optimize / Lane1 [Dual Optimize / Lane1] and [Dual Optimize /
Lane2] must be specified as a set. When these are
Dual Optimize / Lane2 selected, the movement time when changing lanes
and nozzle changeover time is considered.
Single Lane Specify this when producing a job at a single lane.
Dual Lane / Lane1 Specify this when producing a job at lane 1 of a
dual lane machine.
Dual Lane / Lane2 Specify this when producing a job at lane 2 of a
dual lane machine.

20.Click [Next] to display STEP 5.

05OTM-0059Ea

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21.Specify the settings you want to use below.

Setting Description
Display cycle time If this option is selected, then a cycle time graph is displayed
graph during processing.
Allocate parts with If this is selected, parts with many placements will be set in
excessive sequences multiple feeders and placed on multiple modules if possible.
to multiple modules
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup. (The job allocation specified in
step 2 is used.)

22.Specify whether or not reel holders are on feeders by selecting the type from the [Used
feeder type] drop-down list.

• If set to [Reel holder], the optimizer positions feeders in the feeder setup
considering that the feeders have reel holders.
• If set to [Reel holder-E], the optimizer positions feeders in the feeder setup
considering that the feeders do not have reel holders and that a bucket type
feeder pallet is used.
23.If performing paired module production, specify the settings you want to use below.

Setting Description

Optimize panel This specifies whether or not the panel stopping position is
stopping position optimized for paired module production. This is only for M3-
2 modules when they are performing paired module
production.

Optimize for single This specifies whether or not paired module production is
module production used for panels between 250 and 305 in length. This setting
has no bearing for panels outside of this range.
If this is not selected and the panel size is within the range,
the M3-2 modules are automatically paired for paired
production. If this is selected and the panel size is within the
range, the M3-2 modules are not paired.
For panels smaller than the range, M3-2 modules are never
paired. For panels larger than the range, M3-2 modules are
always paired.

Allocate parts in the This specifies whether or not to allocate parts that are in the
interference area to head interference area during paired module production to
M6 modules M6-2 modules if possible. By selecting this option, head
waiting time during paired module production is reduced.
However, more parts are assigned to the M6-2 module.

24.Select the desired feeder usage ratio from the [Feeder usage ratio (Side A : Side B)]
drop-down list. The ratio of feeders is different according to stage type. Refer to the
following tables.

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Stage type: DP-20

Feeder usage ratio

Side A Side B
(Side A : Side B)
2:8 Slot 1.....4 Slot 5.....20
3:7 Slot 1.....6 Slot 7.....20
4:6 Slot 1.....8 Slot 9.....20
5:5 Slot 1...10 Slot 11...20
6:4 Slot 1...12 Slot 13...20
7:3 Slot 1...14 Slot 15...20
8:2 Slot 1...16 Slot 17...20

Stage type: DP245

Feeder usage ratio

(Side A : Side B) Side A Side B

2:8 Slot 1.....9 Slot 10...45

3:7 Slot 1...14 Slot 15...45
4:6 Slot 1...18 Slot 19...45
5:5 Slot 1...23 Slot 24...45
6:4 Slot 1...27 Slot 28...45
7:3 Slot 1...32 Slot 33...45
8:2 Slot 1...36 Slot 37...45

Stage type: TU-M2

Feeder usage ratio

Side A Side B
(Side A : Side B)
2:8
3:7
4:6
5:5 TU-M(A) TU-M(B)
6:4
7:3
8:2

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Stage type: TU-LT (TU-LTC)

Note: Feeders are not allocated to the feeder section of TU-LT(TU-LTC).

Feeder usage ratio

Side A Side B
(Side A : Side B)
2:8
3:7
4:6
5:5 TU-LT(A) TU-LT(B)
6:4
7:3
8:2

25.Click [Next] to display STEP 6.

05OTM-0060Ea

26.Select the feeders that can be used in the [Feeder Available] tab.

27.Select the nozzles that can be used in the [Nozzle Available] tab.

28.Click [Next] to display STEP 7.

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05OTM-0061Ea

29.If all the current settings are correct, click [Next] to display STEP 8 and perform line
balancing.

05OTM-0062Ea

Note: When processing begins, the status is displayed in the [Status] group box. Furthermore, if
the [Display cycle time graph] check box was selected at STEP 5, the [Cycle Time] dialog
box is displayed.

30.When processing is complete, perform one of the following depending on the content of
the message in the [Status] group box.

a. If the message states “Line balance successful”

If the [Cycle Time] dialog box is displayed, the cycle time for each job is shown.
Details of the optimization processing result are output to the report.

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05OTM-0063Ea

• Click [Display Report] to refer to the report. Refer to section " 3.3.2 Reading the
optimization report " for a view of the report.
Click [Save Report] to save the report.
• Click [Save] followed by [Exit] to save the processing content and complete the
line balancing procedure. Alternatively, to exit line balancing without saving the
processing content, click [Exit] and then click [OK] in the confirmation box that
displays.
STEP 8 is then closed.
b. If the message states “Repeating optimization until cancelled...”

The user is responsible for deciding when to terminate the procedure.

• If satisfied with the cycle time displayed in the graph and wishing to save the
processing content and exit line balancing, click [Cancel], [OK], [Save] and
[Finish] in this order.
• Continue processing if not satisfied with the cycle time. It should be noted,
however, that the cycle time may not improve even when continuing. To exit
without saving the processing content, click [Cancel], [OK], [Finish] and [Yes] in
this order.
STEP 8 is then closed.
c. If the message states "Unable to balance the line"

• Click [Error Log] to display the errors from the message group box in a text editor
such as Notepad. Checks the contents of any errors.
Click [Exit] after the checking the content of errors.
STEP 8 is then closed.
Correct any errors using Job Builder and then run NXT AB Mode Multi Job Line
Balancer again.

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3.3.2 Reading the optimization report

The optimization results from NXT AB Mode Multi Job Line Balancer are displayed in the
following report.

(a)

(b)

(c)

(d)

(e)

(e-1)
(e-2)

(f)

(f-1)
(f-2)
(f-3)
(f-4)

05OTM-0067E

(a) Title
(b) Report header

Item Meaning
Date Displays the date when optimization processing was
completed without any errors.
Time Displays the time when optimization processing was
completed without any errors.
User Name Displays the Fuji Flexa logged on user name when
optimization processing was performed.

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(c) Timing report

This section of the report displays the optimized cycle time and changeover time for the jobs
in the order they are to be produced.

Item Meaning
Job Name Displays the name of the job.
Cycle Time (sec.) Displays the cycle time for one panel.
Production Time (min.) This displays the production time which is "Cycle Time" x
"number of panels to produce".
Change Over Time Displays the time for changeover.
(min.)
Group Name Displays the group for the job.
Changeover is not necessary for jobs within the same
group.

(d) Changeover wait time report

This section of the report displays the optimized cycle time and changeover time for each
group.

Item Meaning
Group Displays the name of the group.
Production Time (min.) Displays the total "production time" for all of the jobs
within the same group.
Change Over Time Displays the total "changeover time" for all of the jobs
(min.) within the same group.

(e) Nozzle changer setup report

This section of the report displays the shared nozzle station allocation by machine for all of
the jobs.

e-1. Model name

Displays the model name of the machine in the jobs.

e-2. Nozzle changer setup report

Item Meaning
No Displays the nozzle station socket number.
Result Compares the nozzle allocation to the nozzle allocation for the
[Job used for line or feeder setup] job (from STEP2) and indicates
whether nozzles need to be added, removed, or exchanged.
Add: Add the nozzle.
Delete: Remove the nozzle.
Change: Exchange the nozzle.
Name Displays the name of the nozzle.
Spec Name Displays the specification name for the nozzle.
Diameter Displays the diameter of the nozzle.

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3. Multi Job Line Balancers OTM-FLX-2.5E

Item Meaning
Size X Displays the X-direction size of the nozzle.
Size Y Displays the Y-direction size of the nozzle.
Head Type Displays the specification type for the placing head that can use
that nozzle.
Length Displays the length of the nozzle.

(f) Group
This section of the report displays the shared feeder allocation by machine in groups.

f-1. Group name

Displays the group name for the jobs. The "B1" part of the name changes for each group
because this section is broken into groups.

f-2. Job name

The names of jobs in the same group are displayed in a list. It is possible to perform
production between the jobs within this list without changing the feeder allocation.

Format: "Job Name" / "Panel Side" ("Top", "Bottom")

f-3. Model name

Displays the model name of the machine in the jobs.

When there are multiple machines in the line, a nozzle setup report and feeder setup report
are displayed for each machine model.

f-4. Feeder setup report

Item Meaning
Position Displays the feeder position.
Result Compares the feeder allocation to the feeder allocation for the
[Job used for line or feeder setup] job (from STEP2) and
indicates whether feeders need to be added, removed, or
exchanged.
Add: Add the feeder.
Delete: Remove the feeder.
Change: Exchange the feeder.
Part Number Displays the part number for the part.
Part Comment Displays the part comment for the part.
Type Displays the feeder type.
Width [mm] Displays the width of the reel.
Qty Displays the placing quantity per panel for that position.
Side Displays the side of the feeder pallet to be used.
A: Side A
B: Side B

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3.4 AIMEX Multi Job Line Balancer

AIMEX Multi Job Line Balancer is a tool to create feeder allocations that will result in the
least changeover work and to optimize the placement order. This software is specially
designed for use with AIMEX machines.

AIMEX Multi Job Line Balancer software is an option and a license is required in order to
use it.

05OTM-0115Ea

The following has to be completed/fulfilled before using this application.

• Copy any part data used in the jobs to the part data server because the part data
that is used by the optimizer is taken from the part data server.
• For all of the jobs for which processing is to be performed by the AIMEX Multi
Job Line Balancer, have them all use the same line that includes at least one
AIMEX machine type.
• Because the AIMEX Multi Job Line Balancer cannot change the assignments of
the parts in the jobs, be sure to have all of the necessary parts assigned in each
job beforehand.

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3. Multi Job Line Balancers OTM-FLX-2.5E

3.4.1 Using AIMEX Multi Job Line Balancer

1. Click the [Multi Job Line Balancer] tab in Director and then click the [AIMEX Multi Job
Line Balancer] icon.

05OTM-0116E

The start screen of the AIMEX Multi Job Line Balancer wizard is displayed.

05OTM-0115Ea

Note: Multi Job Line Balancer can also be started by clicking the [Start] button and selecting
[Programs] - [Fuji Flexa] - [MultiJob Line Balancer] - [AIMEX MultiJob LineBalancer].

2. Click [Next] in the AIMEX Multi Job Line Balancer wizard to display STEP 1.

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05OTM-0117Ea

3. Click [Add] to display a job selection dialog box.

05OTM-0118a

4. Select the jobs to be used in the job selection dialog box.

Note: To select multiple jobs, click the jobs while holding down the [CTRL] key.

5. After completing job selection at the job selection dialog box, click [OK]. The job
selection dialog box is then closed and the [Select panel side] dialog box is displayed.

05OTM-0015Ea

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3. Multi Job Line Balancers OTM-FLX-2.5E

6. In the [Select panel side] dialog box, select the panel side for the selected jobs from
[Top], [Bottom] or [Top / Bottom], and then click [OK]. The [Select panel side] dialog box
is then closed, and the selected jobs are added to the list.

05OTM-0119Ea

Setting Description
Name Displays the name of the job.
Revision Displays the revision of the job.
Face Displays the side of the panel for production for the job.
Top: The top side is to be produced.
Bottom: The bottom side is to be produced.
Top/Bottom: Both the top and bottom are to be produced.
Group Displays the group name for the job.
Production Quantity Displays the quantity of panels to be produced.
Prioritizing Displays the side that is to be produced first (top or bottom).
Production When optimizing the production order in STEP 4, this setting
is checked and the production order is determined.
Top: The top side is to be produced before the bottom.
Bottom: The bottom side is to be produced before the top.
Either: A specific order for top or bottom is not specified.

7. Repeat steps 4 to 7 if adding more jobs to the list.

Note: To delete a job from the list, select it and then click [Delete]. To delete all jobs from the list,
click [Clear].

8. When changing the side for which the job is performed, the production quantity, or the
production priority order, select and right click the applicable job and select the
appropriate option from the menu.

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05OTM-0230E

･Selecting the [Enter the production quantity] will display the [Production Quantity]
dialog box.

Enter the production quantity and click [OK].

9. When setting the commonality calculation method, click the [...] button in the upper right
of the screen. The [Commonality Calculation Settings] dialog box displays.

05OTM-0229E

Note: The communality is calculated for the job selected in order to know the level of communality
at which the the parts used in the job are used between jobs.

Select the appropriate option, enter the value as according to requirements, and then
click [OK].

10.When finished adding jobs, click [Next] to display STEP 2.

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05OTM-0120Ea

11.Click the button in the [Job used for line or feeder setup] group box to display a job
list dialog box.

05OTM-0121a

12.Select the name of the job to use as the line and feeder setup at the job list dialog box,
and then click [OK]. The job list dialog box is then closed, and the selected job is
displayed in the [Job used for line or feeder setup] group box.

13.Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job used for line or feeder setup] group box.

14.Select the following option in the [Job used for line or feeder setup] group box if required.

Setting Description
Acquire part data Normally, part data is acquired from the part data server.
from this job However, if this check box is selected, the part data from the job
instead of the selected in [Job used for line or feeder setup] is used.
server.
Caution: When this setting is selected, it is necessary for the
specified job to have all of the part data from all of the
jobs selected in STEP 1.

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15.Select the appropriate option in the [Feeder allocation settings] group box.

Setting Description

Consider the The feeder allocation of the [Job used for line or feeder
allocation of all setup] is used for optimization.
feeders

Consider the Only feeders with a Reserved and Fixed status in the feeder
allocation of allocation of the [Job used for line or feeder setup] are
Reserved and Fixed considered during optimization.The allocation of feeders
feeders only with a Variable status is not considered.

16.Select the appropriate option in the [Settings] group box.

Setting Description
Group jobs for A common feeder allocation for multiple jobs is created and the
batch jobs are grouped. There are times when multiple groups are
changeover. possible. In this case, changeover between groups occurs but
the feeder allocation is not common between groups.
Reduce feeder A common feeder allocation for multiple jobs is created and the
changeover jobs are grouped. There are times when multiple groups are
times. possible. In this case, changeover between groups occurs.
However, the feeder allocation of the previous group is
considered. As a result, a feeder allocation is created that
reduces the changeover of the feeder allocation as much as
possible. Compared to [Group jobs for batch changeover], the
number of feeder changeovers is reduced. However, it is
difficult to balance the cycle time.

17.Click [Next] to display STEP 3.

05OTM-0122Ea

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18.Enter suitable values for each parameter in the [Changeover parameters] group box.

Setting Description
Feeder changeover Specify the time required for one person to change one
(seconds) feeder.
Nozzle changeover Specify the time required for one person to change one
(seconds) nozzle.
Persons Specify the number of people performing changeover at the
same time.
Caution: If "1" is specified, calculation will be performed with
one changeover person for current production and
one changeover person for the next production.

19.When specifying a module for which changeover is not performed, select the module
from the [Select modules for which changeover is not performed] group box.
Note: Specifying a module for which changeover is not performed improves the efficiency rate.

Setting Description

In cases where a feeder cannot Select in cases where changeover is to be

be allocated, allow for allocation permitted on a module for which changeover is
even if it means canceling the not performed has been specified when it is not
locked in changeover. possible to arrange all feeders.

20.Click [Next] to display STEP 4.

05OTM-0123Ea

21.Change the production order if necessary. The production order can be changed
automatically or manually.

Automatic method
a. Click the [Optimize] button if you wish to optimize the production order. A dialog box
displays with an optimization option choice.

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05OTM-0020E

Option Description
Optimize jobs in order to This optimizes the order to minimize the amount of
reduce feeder change times changeover.
Order by production quantity The jobs are ordered based on the quantity of
panels to be produced for each job.

b. Select the desired optimization option in the dialog box and then click [OK]. The
dialog box closes and the production order is changed automatically.

Manual method
a. Select jobs from the list and use the [Up] and [Down] buttons to move them.
b. Specify the panel transport method for each job by right-clicking the desired job and
selecting the appropriate option from the menu.

05OTM-0124Ea

Panel conveyance Description

menu items
Dual Lane / Lane1 Specify this when producing a job at lane 1 of a
dual lane machine.
Dual Lane / Lane2 Specify this when producing a job at lane 2 of a
dual lane machine.
Single Lane Specify this when producing a job at a single lane.
Specify changeover Specify groups for which changeover is performed.
group
When a group is selected the optimum nozzles are
set for each group.

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22.When performing changeover for group units, follow the procedure below to specify the
group settings.

a. Select the [Specify changeover group] check box.

b. Select and right-click the applicable job, then select [Specify changeover group] from
the menu.

c. Enter the changeover group number in the displayed [Specify changeover group]
dialog box and then click [OK].

23.Click [Next] to display STEP 5.

05OTM-0125Eb

24.Specify the settings you want to use.

Setting Description
Display cycle time If this option is selected, then a cycle time graph is displayed
graph during processing.
Allocate parts with If this is selected, parts with many placements will be set in
excessive multiple feeders and placed on multiple modules if possible.
sequences to
multiple modules
Divide parts on fixed When [Allocate parts with excessive sequences to multiple
feeder modules] is selected, you can specify whether to reallocate
parts on fixed feeders.
If this option is selected, parts on fixed feeders can be
allocated to other modules to reduce cycle time.

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Setting Description
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup. (The job allocation specified in
step 2 is used.)
Prioritize Select in cases where feeders are to be exchanged with
changeover for group device parts as priority when changeovers occur.
group device parts

25.Select the [Optimize Auto-Tool to use] check box and select [Processing time limit] from
the drop-down list when optimizing auto-tools.
Note: Processing time limit: The length of time taken for one round of optimization for the auto-
tools to be used.

26.Specify whether or not reel holders are on feeders by selecting the type from the [Used
feeder type] drop-down list.

• If set to [Reel holder], the optimizer positions feeders in the feeder setup
considering that the feeders have reel holders.
• If set to [Reel holder-E], the optimizer positions feeders in the feeder setup
considering that the feeders do not have reel holders and that a bucket type
feeder pallet is used.
27.Select the appropriate option from the drop-down list for each of the following items.

Setting Description

Production Mode [Target Conveyor] becomes available if [Multi] is selected.

Target Conveyor Select the lane to optimize.

28.Click [Next] to display STEP 6.

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29.Select the feeders that can be used in the [Feeder Available] tab.

30.Select the nozzles that can be used in the [Nozzle Available] tab.

31.Click [Next] to display STEP 7.

05OTM-0127Ea

32.If all the current settings are correct, click [Next] to display STEP 8 and perform line
balancing.

05OTM-0128Ea

Note: When processing begins, the status is displayed in the [Status] group box. Furthermore, if
the [Display cycle time graph] check box was selected at STEP 5, the [Cycle Time] dialog
box is displayed.

33.When processing is complete, perform one of the following depending on the content of
the message in the [Status] group box.

a. If the message states “Line balance successful”

If the [Cycle Time] dialog box is displayed, the cycle time for each job is shown.
Details of the optimization processing result are output to the report.

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05OTM-0129Ea

• Click [Display Report] to refer to the report. Refer to section " 3.4.2 Reading the
optimization report " for a view of the report.
Click [Save Report] to save the report.
• Click [Save] followed by [Exit] to save the processing content and complete the
line balancing procedure. Alternatively, to exit line balancing without saving the
processing content, click [Exit] and then click [OK] in the confirmation box that
displays.
STEP 8 is then closed.
b. If the message states “Repeating optimization until cancelled...”

The user is responsible for deciding when to terminate the procedure.

• If satisfied with the cycle time displayed in the graph and wishing to save the
processing content and exit line balancing, click [Cancel], [OK], [Save] and
[Finish] in this order.
• Continue processing if not satisfied with the cycle time. It should be noted,
however, that the cycle time may not improve even when continuing. To exit
without saving the processing content, click [Cancel], [OK], [Finish] and [Yes] in
this order.
STEP 8 is then closed.
c. If the message states "Unable to balance the line"

• Click [Error Log] to display the errors from the message group box in a text editor
such as Notepad. Checks the contents of any errors.
Click [Exit] after the checking the content of errors.
STEP 8 is then closed.
Correct any errors using Job Builder and then run AIMEX Multi Job Line Balanc-
er again.

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3.4.2 Reading the optimization report

The optimization results from AIMEX Multi Job Line Balancer are displayed in the following
report.

(a)

(b)

(c)

(d)

(e)

(f)
(g)

(h)

05OTM-0133E

(a) Title
(b) Report header

Item Meaning
Date Displays the date when optimization processing was
completed without any errors.
Time Displays the time when optimization processing was
completed without any errors.
User Name Displays the Fuji Flexa logged on user name when
optimization processing was performed.

(c) Timing report

This section of the report displays the optimized cycle time and changeover time for the jobs
in the order they are to be produced.

Item Description
Job Name Displays the name of the job.
Cycle Time (sec.) Displays the cycle time for one panel.
Production Time (min.) This displays the production time which is "Cycle Time" x
"number of panels to produce".
Change Over Time Displays the time for changeover.
(min.)

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(d) Group name

Displays the group name for the jobs. The "0" part of the name changes for each group
because this section is broken into groups.
(e) Job name
The names of jobs in the same group are displayed in a list. It is possible to perform
production between the jobs within this list without changing the feeder allocation.
Format: "Job Name" / "Panel Side" ("Top", "Bottom")

(f) Model name

Displays the model name of the machine in the jobs. When there are multiple machines in
the line, a nozzle setup report and feeder setup report are displayed for each machine
model.
(g) Nozzle changer setup report

Item Description
No Displays the nozzle station socket number.
Result Compares the nozzle allocation to the nozzle allocation for the
[Job used for line or feeder setup] job (from STEP2) and indicates
whethexr nozzles need to be added, removed, or exchanged.
Add: Add the nozzle.
Delete: Remove the nozzle.
Change: Exchange the nozzle.
Name Displays the name of the nozzle.
Spec Name Displays the specification name for the nozzle.
Diameter Displays the diameter of the nozzle.
Size X Displays the X-direction size of the nozzle.
Size Y Displays the Y-direction size of the nozzle.
Head Type Displays the specification type for the placing head that can use
that nozzle.
Length Displays the length of the nozzle.

(h) Feeder setup report

Item Description
Position Displays the stage number and the slot number of the feeder.
Result Compares the feeder allocation to the feeder allocation for the
[Job used for line or feeder setup] job (from STEP 2) and
indicates whether feeders need to be added, removed, or
exchanged.
Add: Add the feeder.
Delete: Remove the feeder.
Change: Exchange the feeder.
Part Number Displays the part number for the part.
Part Displays the part comment for the part.
Comment
Type Displays the feeder type.
Width [mm] Displays the width of the reel.
Qty Displays the placing quantity per panel for that position.

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3.5 AIMEX AB Mode Multi Job Line Balancer

AIMEX AB Mode Multi Job Line Balancer is an optimization application that prevents
production stoppages and allows for optimum changeover by dividing the feeder pallets into
two sections so that changeover can be performed at one section while production
continues using the other section.

This application builds on the technology of the AIMEX Multi Job Line Balancer, therefore
optimization is performed with groups that have the same feeder allocation, so changeover
is not needed for jobs within the same group.
Note: If the production amount is small, or depending on the production order, there are cases of
optimization results in which changeover for one side cannot be completed while the other
side is being used in production.

AIMEX AB Mode Multi Job Line Balancer is an option. In order to use this option, an AIMEX
AB Mode Multi Job Line Balancer license and an AIMEX Multi Job Line Balancer license
are required.

05OTM-0162Ea

The following has to be completed/fulfilled before using this application.

• Copy any part data used in the jobs to the part data server because the part data
that is used by the optimizer is taken from the part data server.
• For all of the jobs for which processing is to be performed by the AIMEX AB
Mode Multi Job Line Balancer, have them all use the same line that includes at
least one AIMEX machine type.
• Because the AIMEX AB Mode Multi Job Line Balancer cannot change the
assignments of the parts in the jobs, be sure to have all of the necessary parts
assigned in each job beforehand.
Restrictions
AIMEX AB Mode Multi Job Line Balancer Manual supports the following stage types.

• DP-45
• TU-M2
• TU-LT

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3.5.1 Using AIMEX AB Mode Multi Job Optimizer

1. Click the [Mode Multi Job Line Balancer] tab in Director and then click the [AIMEX AB
Multi Job Line Balancer] icon.

05OTM-0163E

The start screen of the AIMEX AB Mode Multi Job Line Balancer wizard is displayed.

05OTM-0162Ea

Note: AB Mode Multi Job Line Balancer can also be started by clicking the [Start] button and
selecting [Programs] - [Fuji Flexa] - [Multi Job LineBalancer] - [AIMEX AB Mode MultiJob
LineBalancer].

2. Click [Next] in the AIMEX AB Mode Multi Job Line Balancer wizard to display STEP 1.

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05OTM-0164Ea

3. Click [Add] to display a job selection dialog box.

05OTM-0165a

4. Select the jobs to be used in the job selection dialog box.

Note: To select multiple jobs, click the jobs while holding down the [CTRL] key.

5. After completing job selection at the job selection dialog box, click [OK]. The job
selection dialog box is then closed and the [Select panel side] dialog box is displayed.

05OTM-0015Ea

6. In the [Select panel side] dialog box, select the panel side for the selected jobs from
[Top], [Bottom] or [Top / Bottom], and then click [OK]. The [Select panel side] dialog box
is then closed, and the selected jobs are added to the list.

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05OTM-0166Ea

Setting Description
Name Displays the name of the job.
Revision Displays the revision of the job.
Face Displays the side of the panel for production for the job.
Top: The top side is to be produced.
Bottom: The bottom side is to be produced.
Top/Bottom: Both the top and bottom are to be produced.
Group Displays the group name for the job.
Production Quantity Displays the quantity of panels to be produced.
Prioritizing Displays the side that is to be produced first (top or bottom).
Production When optimizing the production order in step 4, this setting is
checked and the production order is determined.
Top: The top side is to be produced before the bottom.
Bottom: The bottom side is to be produced before the top.
Either: A specific order for top or bottom is not specified.

7. Repeat steps 3 to 6 above if adding more jobs to the list.

Note: To delete a job from the list, select it and then click [Delete]. To delete all jobs from the list,
click [Clear].

8. When changing the side for which the job is performed, the production quantity, or the
production priority order, select and right click the applicable job and select the
appropriate option from the menu.

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05OTM-0232E

･Selecting the [Enter the production quantity] will display the [Production Quantity]
dialog box.

Enter the production quantity and click [OK].

9. When setting the commonality calculation method, click the [...] button in the upper right
of the screen. The [Commonality Calculation Settings] dialog box displays.

05OTM-0229E

Note: The communality is calculated for the job selected in order to know the level of communality
at which the the parts used in the job are used between jobs.

Select the appropriate option, enter the value as according to requirements, and then
click [OK].

10.When finished adding jobs, click [Next] to display STEP 2.

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05OTM-0167Ea

11.Click the button in the [Job used for line or feeder setup] group box to display a job
list dialog box.

05OTM-0168a

12.Select the name of the job to use as the line and feeder setup at the job list dialog box,
and then click [OK]. The job list dialog box is then closed, and the selected job is
displayed in the [Job used for line or feeder setup] group box.

13.Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job used for line or feeder setup] group box.

14.Select the following option in the [Job used for line or feeder setup] group box if required.

Setting Description
Acquire part data Normally, part data is acquired from the part data server.
from this job However, if this check box is selected, the part data from the job
instead of the selected in [Job used for line or feeder setup] is used.
server. Caution: When this setting is selected, it is necessary for the
specified job to have all of the part data from all of the
jobs selected in STEP 1.

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15.Select the appropriate option in the [Settings] group box.

Settings Description

Group jobs for batch There are times when multiple groups are possible. In this
changeover. case, changeover between groups occurs. Feeder allocation
is not shared between groups.

Reduce feeder There are times when multiple groups are possible. In this
changeover times. case, changeover between groups occurs. However, the
feeder allocation of the previous group is considered. As a
result, a feeder allocation is created that reduces feeder
allocation changeover as much as possible. Compared to
[Group jobs for batch changeover], the number of feeder
changeovers is reduced. However, it is difficult to balance the
cycle time.

16.Click [Next] to display STEP 3.

05OTM-0169Ea

17.Enter suitable values for each parameter in the [Changeover parameters] group box.

Setting Description
Feeder changeover Specify the time required for one person to change one
(seconds) feeder.
Nozzle changeover Specify the time required for one person to change one
(seconds) nozzle.
Persons Specify the number of people performing changeover at the
same time.
Caution: If "1" is specified, calculation will be performed with
one changeover person for current production and
one changeover person for the next production.

18.Click [Next] to display STEP 4.

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05OTM-0170Ea

19.Change the production order if necessary. The production order can be changed
automatically or manually.

Automatic method
a. Click the [Optimize] button if you wish to optimize the production order. A dialog box
displays with an optimization option choice.

05OTM-0020E

Option Description
Optimize jobs in order to This optimizes the order to minimize the amount of
reduce feeder change times changeover.
Order by production quantity The jobs are ordered based on the quantity of
panels to be produced for each job.

b. Select the desired optimization option in the dialog box and then click [OK]. The
dialog box closes and the production order is changed automatically.

Manual method
a. Select jobs from the list and use the [Up] and [Down] buttons to move them.
b. Specify the panel transport method for each job by right-clicking the desired job and
selecting the appropriate option from the menu.

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05OTM-0171Ea

Panel conveyance Description

menu items
Dual Lane / Lane1 Specify this when producing a job at lane 1 of a
dual lane machine.
Dual Lane / Lane2 Specify this when producing a job at lane 2 of a
dual lane machine.
Single Lane Specify this when producing a job at a single lane.

20.Click [Next] to display STEP 5.

05OTM-0172Ea

21.Specify the settings you want to use below.

Setting Description
Display cycle time If this option is selected, then a cycle time graph is displayed
graph during processing.

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Setting Description
Allocate parts with If this is selected, parts with many placements will be set in
excessive sequences multiple feeders and placed on multiple modules if possible.
to multiple modules
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup. (The job allocation specified in
step 2 is used.)

22.Specify whether or not reel holders are on feeders by selecting the type from the [Used
feeder type] drop-down list.

• If set to [Reel holder], the optimizer positions feeders in the feeder setup
considering that the feeders have reel holders.
• If set to [Reel holder-E], the optimizer positions feeders in the feeder setup
considering that the feeders do not have reel holders and that a bucket type
feeder pallet is used.
23.Select the desired options in the [Single robot AB mode dividing options] group.

Settings Description

Divide left and right For single robot modules, divide each side 1 & 2 into two sides
within sides (A & B).

Divide between side This divides side 1 into side A and side 2 into side B at single
1 and side 2 robot modules.

If the stage types are If the stage types are different, each side is divided into two (A
different, divide left & B). If the stage types are the same, this divides side 1 into
and right within side A and side 2 into side B at single robot modules.
sides.

• Refer to the images below for how the sides are divided and the results for the
different dividing options.

Side 2 Side 2

Side A

Side B

Side 1 Side 1

Divide left and right within sides Divide between side 1 and side 2
05OTM-0173E

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• The used slots for sides A & B when divided into left and right within sides
are shown below.

Stage Type Set side Side A Side B

DP45 Side 1 Slots 1-23 Slots 24-45

Side 2 Slots 24-45 Slots 1-23

TU-M x 2 Side 1 TU-M(A) TU-M(B)

Side 2 TU-M(B) TU-M(A)

Tray unit-LT Side 1 TU-LT (A) TU-LT (B)

(TULT)
Side 2 TU-LT (B) TU-LT (A)

24.Select the desired feeder usage ratio from the [Feeder usage ratio (Side A : Side B)]
drop-down list. The ratio of feeders is different according to stage type. Refer to the
following tables.

Stage type: DP-45

Feeder usage ratio

(Side A : Side B) Side A Side B

2:8 Slot 1.....9 Slot 10...45

3:7 Slot 1...14 Slot 15...45
4:6 Slot 1...18 Slot 19...45
5:5 Slot 1...23 Slot 24...45
6:4 Slot 1...27 Slot 28...45
7:3 Slot 1...32 Slot 33...45
8:2 Slot 1...36 Slot 37...45

Stage type: TU-M2

Feeder usage ratio

Side A Side B
(Side A : Side B)
2:8
3:7
4:6
5:5 TU-M(A) TU-M(B)
6:4
7:3
8:2

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Stage type: TU-LT

Note: Feeders are not allocated to the feeder section of TU-LT.

Feeder usage ratio Side A Side B

(Side A : Side B)
2:8
3:7
4:6
5:5 TU-LT(A) TU-LT(B)
6:4
7:3
8:2

25.Click [Next] to display STEP 6.

05OTM-0174Ea

26.Select the feeders that can be used in the [Feeder Available] tab.

27.Select the nozzles that can be used in the [Nozzle Available] tab.

28.Click [Next] to display STEP 7.

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05OTM-0175Ea

29.If all the current settings are correct, click [Next] to display STEP 8 and perform line
balancing.

05OTM-0176Ea

Note: When processing begins, the status is displayed in the [Status] group box. Furthermore, if
the [Display cycle time graph] check box was selected at STEP 5, the [Cycle Time] dialog
box is displayed.

30.When processing is complete, perform one of the following depending on the content of
the message in the [Status] group box.

a. If the message states “Line balance successful”

If the [Cycle Time] dialog box is displayed, the cycle time for each job is shown.
Details of the optimization processing result are output to the report.

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05OTM-0177Ea

• Click [Display Report] to refer to the report. Refer to section " 3.5.2 Reading the
optimization report " for a view of the report.
Click [Save Report] to save the report.
• Click [Save] followed by [Exit] to save the processing content and complete the
line balancing procedure. Alternatively, to exit line balancing without saving the
processing content, click [Exit] and then click [OK] in the confirmation box that
displays.
STEP 8 is then closed.
b. If the message states “Repeating optimization until cancelled...”

The user is responsible for deciding when to terminate the procedure.

• If satisfied with the cycle time displayed in the graph and wishing to save the
processing content and exit line balancing, click [Cancel], [OK], [Save] and
[Finish] in this order.
• Continue processing if not satisfied with the cycle time. It should be noted,
however, that the cycle time may not improve even when continuing. To exit
without saving the processing content, click [Cancel], [OK], [Finish] and [Yes] in
this order.
STEP 8 is then closed.
c. If the message states "Unable to balance the line"

• Click [Error Log] to display the errors from the message group box in a text editor
such as Notepad. Checks the contents of any errors.
Click [Exit] after the checking the content of errors.
STEP 8 is then closed.
Correct any errors using Job Builder and then run AIMEX AB Mode Multi Job
Line Balancer again.

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3.5.2 Reading the optimization report

The optimization results from AIMEX AB Mode Multi Job Line Balancer are displayed in the
following report.

(a)

(b)

(c)

(d)

(e)

(e-1)
(e-2)

(f)

(f-1)
(f-2)
(f-3)
(f-4)

05OTM-0180E

(a) Title
(b) Report header

Item Meaning
Date Displays the date when optimization processing was
completed without any errors.
Time Displays the time when optimization processing was
completed without any errors.
User Name Displays the Fuji Flexa logged on user name when
optimization processing was performed.

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(c) Timing report

This section of the report displays the optimized cycle time and changeover time for the jobs
in the order they are to be produced.

Item Meaning
Job Name Displays the name of the job.
Cycle Time (sec.) Displays the cycle time for one panel.
Production Time (min.) This displays the production time which is "Cycle Time" x
"number of panels to produce".
Change Over Time Displays the time for changeover.
(min.)
Group Name Displays the group for the job.
Changeover is not necessary for jobs within the same
group.

(d) Changeover wait time report

This section of the report displays the optimized cycle time and changeover time for each
group.

Item Meaning
Group Displays the name of the group.
Production Time (min.) Displays the total "production time" for all of the jobs
within the same group.
Change Over Time Displays the total "changeover time" for all of the jobs
(min.) within the same group.

(e) Nozzle changer setup report

This section of the report displays the shared nozzle station allocation by machine for all of
the jobs.

e-1. Model name

Displays the model name of the machine in the jobs.

e-2. Nozzle changer setup report

Item Meaning
No Displays the nozzle station socket number.
Result Compares the nozzle allocation to the nozzle allocation for the
[Job used for line or feeder setup] job (from STEP2) and indicates
whether nozzles need to be added, removed, or exchanged.
Add: Add the nozzle.
Delete: Remove the nozzle.
Change: Exchange the nozzle.
Name Displays the name of the nozzle.
Spec Name Displays the specification name for the nozzle.
Diameter Displays the diameter of the nozzle.

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Item Meaning
Size X Displays the X-direction size of the nozzle.
Size Y Displays the Y-direction size of the nozzle.
Head Type Displays the specification type for the placing head that can use
that nozzle.
Length Displays the length of the nozzle.

(f) Group
This section of the report displays the shared feeder allocation by machine in groups.

f-1. Group name

Displays the group name for the jobs. The "B1" part of the name changes for each group
because this section is broken into groups.

f-2. Job name

The names of jobs in the same group are displayed in a list. It is possible to perform
production between the jobs within this list without changing the feeder allocation.

Format: "Job Name" / "Panel Side" ("Top", "Bottom")

f-3. Model name

Displays the model name of the machine in the jobs.

When there are multiple machines in the line, a nozzle setup report and feeder setup report
are displayed for each machine model.

f-4. Feeder setup report

Item Meaning
Position Displays the feeder position.
Result Compares the feeder allocation to the feeder allocation for the
[Job used for line or feeder setup] job (from STEP2) and
indicates whether feeders need to be added, removed, or
exchanged.
Add: Add the feeder.
Delete: Remove the feeder.
Change: Exchange the feeder.
Part Number Displays the part number for the part.
Part Comment Displays the part comment for the part.
Type Displays the feeder type.
Width [mm] Displays the width of the reel.
Qty Displays the placing quantity per panel for that position.
Side Displays the side of the feeder pallet to be used.
A: Side A
B: Side B

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3.6 AIM Multi Job Line Balancer

AIM Multi Job Line Balancer is a tool to create feeder allocations that will result in the least
changeover work and to optimize the placement order. This software is specially designed
for use with AIM machines.

AIM Multi Job Line Balancer software is a software option and a license is required in order
to use it.

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The following has to be completed/fulfilled before using this application.

• Copy any part data used in the jobs to the part data server because the part data
that is used by the optimizer is taken from the part data server.
• For all of the jobs for which processing is to be performed by the AIM Multi Job
Line Balancer, have them all use the same line that includes at least one AIM
machine type.
• Because the AIM Multi Job Line Balancer cannot change the assignments of the
parts in the jobs, be sure to have all of the necessary parts assigned in each job
beforehand.

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3.6.1 Using AIM Multi Job Line Balancer

1. Click the [Multi Job Line Balancer] tab in Director and then click the [AIM Multi Job Line
Balancer] icon.

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The start screen of the AIM Multi Job Line Balancer wizard is displayed.

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Note: AIM Multi Job Line Balancer can also be started by clicking the [Start] button and selecting
[Programs] - [Fuji Flexa] - [MultiJob Line Balancer] - [AIM MultiJob Line Balancer].

2. Click [Next] in the AIM Multi Job Line Balancer wizard to display STEP 1.

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3. Click [Add] to display a job selection dialog box.

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4. Select the jobs to be used in the job selection dialog box.

Note: To select multiple jobs, click on the jobs while holding down the [CTRL] key.

5. After completing job selection at the job selection dialog box, click [OK]. The job
selection dialog box is then closed and the [Select panel side] dialog box is displayed.

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6. In the [Select panel side] dialog box, select the panel side for the parts in the selected
jobs from [Top], [Bottom] or [Top / Bottom], and then click [OK]. The [Select panel side]
dialog box is then closed, and the selected jobs are added to the list.

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Setting Description
Name Displays the name of the job.
Revision Displays the revision of the job.
Panel Side Displays the side of the panel for production for the job.
Top: The top side is to be produced.
Bottom: The bottom side is to be produced.
Top/Bottom: Both the top and bottom are to be produced.
Group Displays the group name for the job.
Production Quantity Displays the quantity of panels to be produced.

7. Repeat steps 3 to 6 above if adding more jobs to the list.

Note: To delete a job from the list, select a it and then click [Delete]. To delete all jobs from the
list, click [Clear].

8. When finished adding jobs, click [Next] to display STEP 2.

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9. Click the button in the [Job used for line or feeder setup] group box to display a job
list dialog box.

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10.Select the name of the job to use as the line and feeder setup at the job list dialog box,
and then click [OK]. The job list dialog box is then closed, and the selected job is
displayed in the [Job used for line or feeder setup] group box.

11.Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job used for line or feeder setup] group box.

12.Select the following option in the [Job used for line or feeder setup] group box if required.

Setting Description
Acquire part data Normally, part data is acquired from the part data server.
from this job However, if this check box is selected, the part data from the job
instead of the selected in [Job used for line or feeder setup] is used.
server. Note: When this setting is selected, it is necessary for the
specified job to have all of the part data from all of the
jobs selected in STEP 1.

13.Select the desired option in the [Settings] group box.

Setting Description
Group jobs for A common feeder allocation for multiple jobs is created and the
batch jobs are grouped. There are times when multiple groups are
changeover. possible. In this case, changeover between groups occurs but
the feeder allocation is not common between groups.
Reduce feeder A common feeder allocation for multiple jobs is created and the
changeover jobs are grouped. There are times when multiple groups are
times. possible. In this case, changeover between groups occurs.
However, the feeder allocation of the previous group is
considered. As a result, a feeder allocation is created that
reduces the changeover of the feeder allocation as much as
possible. Compared to [Group jobs for batch changeover], the
number of feeder changeovers is reduced. However, it is
difficult to balance the cycle time.

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14.Enter suitable values for each parameter in the [Changeover parameters] group box.

Setting Description
Feeder changeover Specify the time required for one person to change one
(seconds) feeder.
Persons Specify the number of people performing changeover at the
same time.
Note: If "1" is specified, calculation will be performed with
one changeover person for current production and
one changeover person for the next production.

15.Click [Next] to display STEP 3.

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16.Change the production order if necessary. The production order can be changed
automatically or manually.

Automatic method
a. Click the [Optimize] button if you wish to optimize the production order. A dialog box
displays with an optimization option choice.

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Option Description
Optimize jobs in order to This optimizes the order to minimize the amount of
reduce feeder change times changeover.
Order by production quantity The jobs are ordered based on the quantity of
panels to be produced for each job.

b. Select the desired optimization option in the dialog box and then click [OK]. The
dialog box closes and the production order is changed automatically.

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Manual method
a. Select jobs from the list and use the [Up] and [Down] buttons to move them.

17.Click [Next] to display STEP 4.

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18.Select the [Divide feeders] check box if required.

19.Specify the whether of not reel holders are on the feeders by selecting the type from the
[Used feeder type] drop-down list.

• If set to [Reel holder], the optimizer positions feeders in the feeder setup
considering that the feeders have reel holders.
• If set to [Reel holder-E], the optimizer positions feeders in the feeder setup
considering that the feeders do not have reel holders and that a bucket type
feeder pallet is used.
20.Select the [Optimize nozzle station(s) (H12, H08, H04, H01) (Experimental)] check box
if required.

21.Click [Next] to display STEP 5.

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22.Select the machine for which to specify settings from the drop-down list.

23.Select the feeders that can be used in the [Feeder Available] tab.

24.Select the nozzles that can be used in the [Nozzle Available] tab.

25.When specifying settings for multiple machines, perform the previous three steps for
each machine.

26.Click [Next] to display STEP 6.

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27.If all the current settings are correct, click [Next] to display STEP 7 and perform line
balancing.

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28.When processing is complete, perform one of the following depending on the content of
the message in the upper part of screen.

a. If the message states “Line balance successful”

If the [Cycle Time] dialog box is displayed, the cycle time for each job is shown.
Details of the optimization processing result are output to the report.

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• Click [Display Report] to refer to the report. Refer to section " 3.6.2 Reading the
optimization report " for a view of the report.
Click [Save Report] to save the report.
• Click [Save] followed by [Exit] to save the processing content and complete the
line balancing procedure. Alternatively, to exit line balancing without saving the
processing content, click [Exit] and then click [OK] in the confirmation box that
displays.
STEP 7 is then closed, along with the [Cycle Time] dialog box if it is displayed.

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b. If the message states “Repeating optimization until cancelled...”

The user is responsible for deciding when to terminate the procedure.

• If satisfied with the cycle time displayed in the graph and wishing to save the
processing content and exit line balancing, click [Cancel], [OK], [Save] and
[Finish] in this order.
• Continue processing if not satisfied with the cycle time. It should be noted,
however, that the cycle time may not improve even when continuing. To exit
without saving the processing content, click [Cancel], [OK], [Finish] and [Yes] in
this order.
The STEP 7 screen is then closed, as is the [Cycle Time] dialog box if displayed.
c. If the message states "Unable to balance the line"

• Click [Error Log] to display the errors from the message group box in a text editor
such as Notepad. Checks the contents of any errors.
• Click [Exit] after the checking the content of errors. STEP 7 is then closed, along
with the [Cycle Time] dialog box if displayed. Correct any errors using Job
Builder and then run AIM Multi Job Line Balancer again.

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3.6.2 Reading the optimization report

The optimization results from AIM Multi Job Line Balancer are displayed in the following
report.

(a)

(b)

(c)

(d)
(e)

(f)

(g)

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(a) Title
(b) Report header

Item Meaning
Date Displays the date when optimization processing was
completed without any errors.
Time Displays the time when optimization processing was
completed without any errors.
User Name Displays the Fuji Flexa logged on user name when
optimization processing was performed.

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(c) Timing report

This section of the report displays the optimized cycle time and changeover time for the jobs
in the order they are to be produced.

Item Meaning
Job Name Displays the name of the job.
Cycle Time (sec.) Displays the cycle time for one panel.
Production Time (min.) This displays the production time which is "Cycle Time" x
"number of panels to produce".
Change Over Time Displays the time for changeover.
(min.)

(d) Group name

Displays the group name for the jobs. The "0" part of the name changes for each group
because this section is broken into groups.

(e) Job name

The names of jobs in the same group are displayed in a list.
It is possible to perform production between the jobs within this list without changing the
feeder allocation.

Format: "Job Name" / "Panel Side" ("Top", "Bottom")

(f) Model name

Displays the model name of the machine in the jobs.

When there are multiple machines in the line, a nozzle setup report and feeder setup report
are displayed for each machine model.

(g) Feeder setup report

Item Meaning
Position Displays the feeder position.
Result Compares the feeder allocation to the feeder allocation for the
[Job used for line or feeder setup] job (from step 2) and indicates
whether feeders need to be added, removed, or exchanged.
Add: Add the feeder.
Delete: Remove the feeder.
Change: Exchange the feeder.
Part Number Displays the part number for the part.
Part Displays the part comment for the part.
Comment
Type Displays the feeder type.
Width [mm] Displays the width of the reel.
Qty Displays the placing quantity per panel for that position.

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4. Optimizing
After balancing the line, the sequences for each machine need to be arranged in the
optimum order to minimize cycle time. The optimizer is used to arrange the sequences in
the best order for the selected machines.

The optimizer is used to arrange parts and placement sequences in the best order. In
addition to the optimizer within Job Builder, there are other optional optimizers for
optimizing different jobs or sides.

For NXT-series machines, NXT Dual Production Optimizer and NXT Triple Production
Optimizer are capable of optimizing multiple different jobs to run on different lanes or two
sides of a panel using different lanes.

4.1 Optimize in Job Builder

1. Select [Optimize] from the [Tools] menu to display the [Optimize Options] dialog box.

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Setting Description

[Fixes existing feeders] Select this when you do not want to change the
current feeder allocation.

[Reallocates feeders] Select this to optimize the feeder allocation.

[Reselects feeders] Select this to specify only the feeder types again
without changing the current feeder allocation.
Note: If you select this and perform optimization,
the settings for [Feeder Name] in the
[Feeder Setup] tab in the machine
configuration are set again.

[Reselects and Reallocates Select this to set the feeder type again, and to
feeders] optimize the feeder allocation.
Note: If you select this and perform optimization,
the settings for [Feeder Name] in the
[Feeder Setup] tab in the machine
configuration are set again.

2. Select the applicable [Feeder Setup] option and then click [OK]. Then click [OK] to
display the [Select Machine] dialog box.

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3. Select the desired machines, then click [Start].

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4. The [Optimize] dialog box displays. In this dialog box, the status of the optimization
process displays along with any errors. If any errors occur, click [Error Details] to display
further details. Click [Close] when the optimization process is complete.

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4.2 NXT Multi Machine Optimizer

Generally, an NXT line consists of "one" NXT machine (made up of multiple bases). With
this configuration, line balancing is very simple and all of the parts are simply assigned to
the NXT machine. The parts assigned to the various modules is optimized and rearranged
during the optimization process. However, if the NXT line is comprised of multiple NXT
"machines", then use this software to line balance and optimize the job.

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The job must be in the condition below before using this software.

• The line must be already selected in the job.

• The basic configuration of the line must already be set (number and type of
modules and if not doing head or nozzle optimization, the heads and nozzles for
each module).

• All of the marks to be used must be assigned to the machines.

• All of the parts to be placed must be assigned to at least one machine. (This
software does not assign unassigned parts; it just moves assigned parts from
one machine to another.)

• The settings in the [General] tab of the machine configuration for the second and
later machines are the same as the first machine settings.

When using the function to limit the number of feeders that can be used per part number,
install the separate application for this function.

How to install the application software

Obtain the installation disk labeled "Flexible Assembly Software".

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• When the installation disk is a DVD-ROM

1. Insert the Fuji Flexa installation DVD-ROM into the disk drive of the computer.

2. Use the scroll bar to display “Specify divided

feeder quantity per part type at NXT/AIMEX
Multi Machine Optimizer”.

3. Click [Specify divided feeder quantity per part

type at NXT/AIMEX Multi Machine Optimizer].

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4. Click [Yes] in the dialog box that displays.

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• When the installation disk is a CD-ROM

1. Insert the Fuji Flexa installation CD-ROM into the disk drive of the computer.

2. Open the [Limit Feeder Duplication] folder and double-click the [Feeder Duplication.xls]
file to open it.

3. Click [Yes] in the dialog box that displays.

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4.2.1 Using NXT Multi Machine Optimizer

1. Click the [Optimizer] tab in Director and then click the [NXT Multi Machine Optimizer]
icon.

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The start screen of the NXT Multi Machine Optimizer wizard is displayed.

05OTM-0087Eb

Note: NXT Multi Machine Optimizer can also be started by clicking the [Start] button and selecting
[Programs] - [Fuji Flexa] - [Optimizer] - [NXT Multi Machine Optimizer].
Note: NXT Multi Machine Optimizer can also be started by selecting [NXT Multi Machine
Optimizer] from the [Tools] menu in Job Builder.

2. Click [Next] in the NXT Multi Machine Optimizer wizard to display STEP 1.

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3. Click the button in the [Job] group box to display a job list dialog box.

05OTM-0090

4. Select the job to be used in the job list dialog box, and then click [OK]. The job list dialog
box is then closed, and the selected job is displayed in the [Job] group box, and the line
configuration of the selected job is displayed in the [Line Configuration] group box.

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5. Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job] group box (Top or Bottom).

6. Select the check boxes as required (explanations are given in the table below).

Setting Description
Optimizes the entire When selected, the entire NXT line is line balanced and
NXT line optimized. If option is not selected, then only the machine
selected in the [Line Configuration] list is optimized (if no
machines are selected, then the first machine is
automatically selected).
Support XPF Select this option if there are XPF machines in the line with
the NXT. By selecting this, the XPF will be considered
during optimization of the NXT machines.

7. Click [Next] to display STEP 2.

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8. Specify the settings for the conveyor in the [Conveyor Settings] group box.

Setting Description
Conveyor Mode This setting specifies the panel conveyance mode to be used
for production for determining optimization.
Board Flow This specifies the direction in which the panels flow through the
machine.
[Left -> Right]: Flows left to right when viewing from in front
of the machine.
[Right -> Left]: Flows right to left when viewing from in front
of the machine.
These settings do not actually control the direction in the
machine but are used for job related processing in Fuji Flexa.
Lane 2 reference rail This specifies whether or not the reference rail for the second lane
setting can move to different positions.
If this is set to "Fixed" the reference rail cannot move to
different positions and a setting must be specified for [Interval
between lane 1 and 2 (mm)].

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Setting Description
Interval between This setting is only available when the setting for [Lane 2
lane 1 and 2 (mm) reference rail setting] is "Fixed".
This setting specifies the location at which the reference rail
for lane 2 will be fixed.
Target Conveyor This specifies the target lane on which the job will be
optimized.
If set to "Lane 1", then the job is optimized with the premise
that the panels are to be loaded on lane 1.
Optimize for dual When this is selected, optimization is performed for dual lane
lane production with production using the same job for both lanes.
same job names.

9. If performing paired module production, then specify the desired settings in the [Paired
Module Production] group box.

Setting Description
Optimize For Single This specifies whether or not paired module production is
Module Production used for panels between 250 and 305 mm in length. This
setting has no bearing for panels outside of this range.
M3 / M3-2 modules are automatically paired for paired
production. If this is selected and the panel size is within the
range, the M3 / M3-2 modules are not paired.
For panels smaller than the range, M3 / M3-2 modules are
never paired. For panels larger than the range, M3 / M3-2
modules are always paired.
Optimize Panel This specifies whether or not the panel stopping position is
Stopping Position optimized for paired module production. This is only for M3 /
Offset M3-2 modules when they are performing paired module
production.
Automatically This specifies whether or not to optimize the configuration of
configure M3 paired paired modules for panels between 250 and 305 in length.
modules When this is selected, optimization is performed for each
module determining whether to perform paired module
production or not.
This setting is only used when performing single module
production on panels 305 mm or less in length and when
optimizing the panel stopping position.
Allocate parts in the This specifies whether or not to allocate parts that are in the
interference area of head interference area (one module has to wait while the
M3 paired modules other module is in that area) during M3 paired module
to M3 paired production to M3 paired modules.
modules
This setting is only used when performing single module
production on panels 305 mm or less in length.
Allocate Parts To This specifies whether or not to allocate parts that are in the
M6 Module head interference area during paired module production to M6
/ M6-2 modules if possible. By selecting this option, head
waiting time during paired module production is reduced.
However, more parts are assigned to the M6 / M6-2 module.

10.Click [Next] to display STEP 3.

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11.Select the appropriate check boxes in the [Optimization options] group box while
referring to the following table.
Note: Head optimization does not change the heads on modules with OF or G04 heads, nor can
it allocate these heads. These are special heads and if they are being used, then they
should be specified in their modules in the job before using NXT Multi Machine Optimizer.

Setting Description
Reallocate feeders If this option is selected, then feeders that have a variable
status can be moved or even deleted if they are not needed
during optimization.
If this option is not selected, then already existing feeders
cannot be moved or deleted and any newly required feeders
can be set in empty slots only.
Allocate parts with This specifies whether or not parts with many placements will
excessive be broken up into multiple feeders and set into different
sequences to modules.
multiple modules
If this is selected, parts with many placements can be set in
multiple feeders and placed on multiple modules if possible.
Divide parts on Specify whether to reallocate parts on fixed feeders when
fixed feeders [Allocate parts with excessive sequences to multiple modules]
is selected.
When this is selected, parts on fixed feeders can be allocated
to other modules to reduce cycle time.
Optimize insert When this is not selected, insert order, feeders, head setup,
order only nozzle stations and other items can be optimized/changed
during optimization.
Only the insert order is changed during optimization when this
is selected.
Use current feeder If select [Yes], then the new feeder arrangement is created by
setup using current feeder positions and settings.
If select [No], then the current feeder positions and settings
are completely ignored and all feeders are redistributed.

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Setting Description
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup.
Nozzle station Specify the nozzle station nozzle arrangement method.
nozzle allocation
method • "Minimum" arranges for the minimum number nozzles
required by the head.

• "Maximum" arranges for the maximum number of nozzles

allowable in the station.
Optimizer type This setting specifies the level of optimization to be performed.
• [Speed] performs optimization with a priority on achieving
a relatively fast cycle time and processing is performed
quickly.

• [Optimal] performs optimization with a priority on achieving

the fastest cycle time and processing takes longer.

• [Time Limit] performs processing the same as [Optimal] but

within a specified time limit.
Processing time This only displays if [Optimizer Type] is set to [Time Limit].
limit This specifies the time limit in minutes that the optimizer has
to complete processing.
Used feeder type Specify the whether of not reel holders are on the feeders.
• If set to [Reel holder], the optimizer positions feeders in the
feeder setup considering that the feeders have reel holders.

• If set to [Reel holder-E], the optimizer positions feeders in

the feeder setup considering that feeders have no reel
holders and a bucket type feeder pallet is used.
Performs basic When this is selected, the setup of the heads is considered
head optimization during optimization and the heads/nozzle stations used are
changed to best suit the job.
The GL, G04 and OF heads are not considered when using
this option and will not be moved, added, or deleted because
these are special head types. If using these head types,
manually set them in the job before optimizing.
In addition, the quantity and head types available for
optimization are specified in the STEP 4 when this option is
selected. When this option is not selected, STEP 4 is skipped.

12.Click [Next].

If the [Performs basic head optimization] option was selected in the previous step,
STEP 4 is displayed.

In all other cases, STEP 5 is displayed.

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13.If you selected [Performs basic head optimization] earlier, select heads to be used by
selecting check boxes in the [Head Quantity] group. Enter a value for the quantity of
each head available.
Note: If the value is left at 0, then the optimizer will considers there to be no limit to the number of
heads for that type. If a head type is not available, then clear the check box for that head
type.

14.Click [Next].
STEP 5 is displayed.

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15.Specify the maximum number of divided feeders.

Caution: A feeder may be duplicated fewer times than was specified.

• To specify the number of divided feeders for each part number, press the
[Settings] button. A dialog box for specifying the maximum number of divided
feeders for each part number will display.

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Item Explanation

PartNumber Displays the part number of the part assigned to the

machine for optimization.

Number of Displays the quantity of parts assigned to the

placements machine for optimization.

Number of Specify the maximum number of feeders that can

duplicated feeders be divided.

(Initially any previous values are displayed.)

a. Enter the required quantity into the [Number of Duplicated Feeders] column.
Caution: If "No" is specified for the [Allow Multiple Slots] setting in the part data for a part, feeders
are not duplicated for that part even if a quantity is specified in this step for that part number.

If you want to enter the same feeder quantity for all part numbers, click [Batch Input]
to display a dialog box for entering the value. Enter the desired value for all of the
part numbers and click [OK].

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b. Click [OK] to save the entered values.

• By clicking the [Settings] button in [Specify the number of divided feeders based
on the number of placements], a dialog box will display which will allow
specification of the quantity of divided feeders based on the number of
placements.

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a. Enter the number of placements for the feeder division quantity into the quantity
restriction area. Specify "0" to set no restrictions on the number of duplicated
feeders.

There is no duplication for up to 170 placements when performing settings as shown

in the above screen. Division is performed once for up to 350 placements. There is
no restriction for 351 placements or greater.

b. Click [OK] to save the entered values.

16.Click [Next].
STEP 6 is displayed.

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17.Select the [Optimizes only the designated module] check box if required.

Setting Description
Optimizes only the When selected, only optimization for the modules selected
designated module from the list below this setting is performed.
When this is not selected, optimization for all modules is
performed.

18.Click [Next].
When selecting a job which does not use a DX head in STEP 1, STEP 8 displays. (In
this case, go to STEP 19.)
When selecting a job which uses a DX head, STEP 7 displays.

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05OTM-0225E

Setting Description

Optimize Auto-Tool The optimum auto-tool configuration is set taking into

configuration. account the quantity of auto-tools owned.

Number of Auto- The configuration is optimized for the quantity of auto-tools

Tools owned entered.

Preferred multiple The auto-tool configuration is calculated in a way that more

set Auto-Tool. of the specified auto-tools are assigned into one module.

Optimize Auto-Tool The auto-tools that are used for production are set based on
to use. the auto-tool configuration specified in the job.

Processing time limit Specify the processing time limit for one round of
optimization for the auto-tools to be used.

19.Click [Next].
STEP 8 displays and multi machine optimization is performed.
When processing begins, the status is displayed in the upper screen.

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When processing is complete, the results and cycle times are displayed.

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20.Click [Save] to save the results of optimization and reflect them in the job.
Note: If this step is not performed, then none of the results of the optimization are reflected in the
job.

21.Click [Cancel] to close STEP 8 and exit NXT Multi Machine Optimizer.

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4.3 NXT Dual Production Optimizer

This is used for the NXT when performing dual lane production with different jobs in lanes
1 and 2, to create the optimal placement order of parts already assigned to the NXT and
the optimal feeder allocation for the two jobs.

After the jobs are created, jobs for both lanes are optimized.

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In order to use this software, jobs must satisfy the following condition.

• Jobs (one or two) that you wish to optimize must be in a state in which
production is possible.

4.3.1 Using NXT Dual Production Optimizer

1. Click the [Optimizer] tab in Director and then click the [NXT Dual Production Optimizer]
icon.

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The start screen of the NXT Dual Production Optimizer wizard is displayed.

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05OTM-0098Ea

Note: NXT Dual Production Optimizer can also be started by clicking the [Start] button and
selecting [Programs] - [Fuji Flexa] - [Optimizer] - [NXT Dual Production Optimizer].

2. Select either [Produce two different jobs.] or [Produce the Top and Bottom sides on the
same job.].

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3. Click the button in the [Lane1] group box to display a job list dialog box.

05OTM-0100

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4. Select the job to be used in the job list dialog box, and then click [Ok]. The job list dialog
box is then closed, and the selected job is displayed in the [Lane1] group box.
Note: If [Produce the Top and Bottom sides on the same job.] is selected, the selected job name
is displayed in [Lane2] group box.

5. Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Lane1] group box (Top or Bottom).

6. If [Produce two different jobs.] is selected, click the button in the [Lane2] group box.
A job list dialog box is displayed. Select the job to be used in the job list dialog box, and
then click [Ok]. The job list dialog box is then closed, and the selected job is displayed
in the [Lane2] group box.

7. If [Produce two different jobs.] is selected, select which panel side’s feeder setup is to
be used for that job from the drop-down list in the [Lane2] group box (Top or Bottom).

8. By selecting the [Repeatedly performing optimization] check box to automatically

change the conditions and repeatably perform optimization, a good cycle time can be
generated. Optimization is performed until [Cancel] is clicked and the best result from
optimizing up to that point is saved.

9. Click [Next] to display STEP 2.

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10.Select machines to be optimized in the list.

11.If the [Repeatedly performing optimization] check box is selected in STEP 1, the [Option]
group box displays. Ether the length of time at which optimization is stopped.
Note: When the time specified here is reached, the current optimization is canceled and
optimization is started again under different conditions.

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12.Click [Next] to display STEP 3.

05OTM-0102Eb

13.Refer to the table below for details regarding the [Optimizer options] settings.

Setting Description
Calculate the cycle If this selected, optimization is not performed and only cycle
time only time is calculated.
Reallocate feeders If this selected, feeder allocation is optimized.
If this is not selected, optimization is performed using the
currently specified feeder allocation. Select [Lane 1], [Lane 2],
or [Lane 1, Lane 2] from the [Used feeder positions] drop-
down list.
Allocate parts with If this is selected, then any current positions for feeders are not
excessive changed and new feeders are only allocated to open places.
sequences to
multiple modules If this is not selected, then the current feeder positions and
settings are completely ignored and all feeders are
redistributed.
Divide parts on Specify whether to reallocate parts on fixed feeders when
fixed feeders [Allocate parts with excessive sequences to multiple modules]
is selected.
When this is selected, parts on fixed feeders can be allocated
to other modules to reduce cycle time.
Optimize panel This specifies whether or not the panel stopping position is
stopping position optimized for paired module production.
for paired module
production The left half of the feeder pallet is used for lane 1 feeders and
the right half of the feeder pallet is used for lane 2 feeders.
Allocate parts in the If this is selected, the panel stopping position offset is set
interference area to automatically during optimization.
M6 modules
Optimize for single This specifies whether or not paired module production is
module production used for panels between 250 and 305 in length.

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Setting Description
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup.
Optimize using If the check box is selected and optimization is performed, the
“optimal” as the optimization process will continue to be performed until
optimizer type optimization is canceled and [OK] is selected in the
confirmation dialog box.
However, it will finish in the event where optimization cannot
be improved any further.

Note: [Divide the slots and set up 2 different jobs] means the left half of the feeder pallet is used
for lane 1 feeders and the right half of the feeder pallet is used for lane 2 feeders

14.Click [Next] to display STEP 4 and perform dual production optimization. When
processing begins, the status is displayed in the upper part of the screen.

05OTM-0103Ea

When processing is complete, the results and cycle times are displayed.

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Note: Click [Report] to display the the cycle times in a text editor such as Notepad.

15.Click [Save] to save the optimization results and reflect them in the job.
Note: If this step is not performed, then none of the results of the optimization are reflected in the
job.

16.Click [Cancel] to close STEP 4 and exit NXT Dual Production Optimizer.

Note: If optimization fails, click the [Error Log] button to display the content of any errors in a text
editor such as Notepad

05OTM-0105E

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4.4 NXT Triple Production Optimizer

This is used for the NXT when performing triple lane production with different jobs in lanes
1, 2, and 3 to create the optimal placement order of parts already assigned to the NXT and
the optimal feeder allocation for the three jobs.

When a production job is created, the job is optimized for the three lanes.

05OTM-0106E

In order to use this software, jobs must satisfy the following condition.

• Jobs (one, two, or three) that you wish to optimize must be in a state in which
production is possible.

4.4.1 Using NXT Triple Production Optimizer

1. Click the [Optimizer] tab in Director and then click the [NXT Triple Production Optimizer]
icon to display the NXT Triple Production Optimizer wizard.

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The start screen of the NXT Triple Production Optimizer wizard is displayed.

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05OTM-0106E

Note: NXT Triple Production Optimizer can also be started by clicking the [Start] button and
selecting [Programs] - [Fuji Flexa] - [Optimizer] - [NXT Triple Production Optimizer].

2. Specify the production method from the following choices.

• [All lanes produce the same job]

• [Lane 1 and lane 2 produce the same job, while lane 3 produces a different job]

• [Each lane produces a different job]

3. Click [Next] to display STEP 2.

05OTM-0108E

4. If [Lane 1 and lane 2 produce the same job, while lane 3 produces a different job] was
selected in STEP 1, select either [Produce two different jobs] or [Produce the Top and
Bottom sides on the same job].

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5. Select the job to optimize for each lane. The selectable lanes depend on the options
selected above and in STEP 1.

Selected option Job setting group box

STEP 1 STEP 2
All lanes produce the same job [Lane1]
Lane 1 and lane 2 produce Produce two different [Lane1], [Lane3]
the same job, while lane 3 jobs.
produces a different job
Produce the Top and [Lane1]
Bottom sides on the
same job.
Each lane produces a different job [Lane1], [Lane2],
[Lane3]

Method of selecting job

a. Click the button in each group box of [Lane1], [Lane2], and [Lane3] to display a
dialog box.

05OTM-0109

b. Select the job to be used in the job list dialog box, and then click [Ok]. The job list
dialog box is then closed, and the selected job is displayed in the relevant group box.

c. Select which panel side’s feeder setup is to be used for that job from the drop-down
list in each group box (Top or Bottom).

6. Click [Next] to display STEP 3.

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05OTM-0110E

7. Select machines to be optimized in the list.

8. Click [Next] to display STEP 4.

05OTM-0111E

9. Select the desired [Optimizer Option] settings. Refer to the table below for details
regarding the settings.

Setting Description
Calcurate the cycle If this selected, optimization is not performed and only cycle
time only time is calculated.
Reallocate feeders If this selected, feeder allocation is optimized.
If this is not selected, optimization is performed using the
currently specified feeder allocation. Select [Lane 1], [Lane 2],
or [Lane 1, Lane 2] from the [Used feeder positions] drop-
down list.
Allocate parts with If this is selected, then any current positions for feeders are not
excessive changed and new feeders are only allocated to open places.
sequences to
multiple modules If this is not selected, then the current feeder positions and
settings are completely ignored and all feeders are
redistributed.

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Setting Description
Divide parts on Specify whether to reallocate parts on fixed feeders when
fixed feeders [Allocate parts with excessive sequences to multiple modules]
is selected.
When this is selected, parts on fixed feeders can be allocated
to other modules to reduce cycle time.
Optimize for single This specifies whether or not paired module production is
module production used for panels between 250 and 305 in length.
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup.

10.Click [Next] to display STEP 5 and perform triple production optimization. When
processing begins, the status is displayed in the upper part of the screen.

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When processing is complete, the results and cycle times are displayed.

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05OTM-0113E

Note: Click [Report] to display the cycle times in a text editor such as Notepad.

11.Click [Save] to save the results of optimization and reflect them in the job.
Note: If this step is not performed, then none of the results of the optimization are reflected in the
job.

12.Click [Cancel] to close STEP 5 and exit NXT Triple Production Optimizer.

Note: If optimization fails, Click [Error Log] to display the content of any errors in a text editor such
as Notepad.

05OTM-0114E

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4.5 AIMEX Multi Machine Optimizer

Generally, an AIMEX line consists of "one" AIMEX machine (made up of multiple bases).
With this configuration, line balancing is very simple and all of the parts are simply assigned
to the AIMEX machine. The parts assigned to the various modules is optimized and
rearranged during the optimization process. However, if the AIMEX line is comprised of
multiple AIMEX "machines", then use this software to line balance and optimize the job.

05OTM-0134Eb

The job must be in the condition below before using this software.

• The line must be already selected in the job.

• The basic configuration of the line must already be set (number and type of
modules and if not doing head or nozzle optimization, the heads and nozzles for
each module).

• All of the marks to be used must be assigned to the machines.

• All of the parts to be placed must be assigned to at least one machine. (This
software does not assign unassigned parts; it just moves assigned parts from
one machine to another.)

When using the "specify the number of part numbers for each part number" function, install
the separate application for this function.

How to install the application software

Obtain the installation disk labeled "Flexible Assembly Software".

• When the installation disk is a DVD-ROM

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1. Insert the Fuji Flexa installation DVD-ROM into the disk drive of the computer.

2. Use the scroll bar to display “Specify divided

feeder quantity per part type at NXT/AIMEX
Multi Machine Optimizer”.

3. Click [Specify divided feeder quantity per part

type at NXT/AIMEX Multi Machine Optimizer].

05SET-0182E

4. Click [Yes] in the dialog box that displays.

05OTM-0181E

• When the installation disk is a CD-ROM

1. Insert the Fuji Flexa installation CD-ROM into the disk drive of the computer.

2. Open the [Limit Feeder Duplication] folder and double-click the [Feeder Duplication.xls]
file to open it.

3. Click [Yes] in the dialog box that displays.

05OTM-0181E

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4.5.1 Using AIMEX Multi Machine Optimizer

1. Click the [Optimizer] tab in Director and then click the [AIMEX Multi Machine Optimizer]
icon.

05OTM-0135E

The start screen of the AIMEX Multi Machine Optimizer wizard is displayed.

05OTM-0134Eb

Note: AIMEX Multi Machine Optimizer can also be started by clicking the [Start] button and
selecting [Programs] - [Fuji Flexa] - [Optimizer] - [AIMEX Multi Machine Optimizer].

2. Click [Next] in the AIMEX Multi Machine Optimizer wizard to display STEP 1.

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05OTM-0136Eb

3. Click the button in the [Job] group box to display a job list dialog box.

05OTM-0137

4. Select the job to be used in the job list dialog box, and then click [OK]. The job list dialog
box is then closed, and the selected job is displayed in the [Job] group box, and the line
configuration of the selected job is displayed in the [Line Configuration] group box.

05OTM-0138Eb

5. Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job] group box (Top or Bottom).

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6. Select the check boxes as required (explanations are given in the table below).

Setting Description
Optimizes the entire When selected, the entire AIMEX line is line balanced and
AIMEX line optimized. If option is not selected, then only the machine
selected in the [Line Configuration] list is optimized (if no
machines are selected, then the first machine is
automatically selected).

7. Click [Next] to display STEP 2.

05OTM-0139Ec

8. Specify the settings for the conveyor in the [Conveyor Settings] group box.

Setting Description
Conveyor Mode This setting specifies the panel conveyance mode to be used
for production for determining optimization.
Board Flow This specifies the direction in which the panels flow through
the machine.
[Left -> Right]: Flows left to right when viewing from in front
of the machine.
[Right -> Left]: Flows right to left when viewing from in front
of the machine.
These settings do not actually control the direction in the
machine but are used for job related processing in Fuji Flexa.
Lane 2 reference rail This specifies whether or not the reference rail for the second
setting lane can move to different positions.
If this is set to "Fixed" the reference rail cannot move to
different positions and a setting must be specified for [Interval
between lane 1 and 2 (mm)].
Interval between This setting is only available when the setting for [Lane 2
lane 1 and 2 (mm) reference rail setting] is "Fixed".
This setting specifies the location at which the reference rail
for lane 2 will be fixed.

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Setting Description
Distance from the This is available if the [Both lanes towards their feeder pallet]
first rail to the fourth check box is selected.
rail (mm)
This specifies the distance between the first rail and the
fourth rail.
Production Mode This specifies whether to perform standard production or
multi production.
Target Conveyor This specifies the target lane on which the job will be
optimized. If set to "Lane 1", then the job is optimized with
the premise that the panels are to be loaded on lane 1.
Optimize for dual When this is selected, optimization is performed for dual lane
lane production with production using the same job for both lanes.
same job names.
This is unavailable if "Multi" is selected for [Production Mode].

9. Click [Next].

If "Normal" was selected for [Production Mode] in step 2, step 4 displays. (In this case,
go to step 12.)

If "Multi" was selected for [Production Mode] in step 2, step 3 displays.

05OTM-0186Ea

10.Specify the size of the panel (X, Y) for the opposite lane.

11.Click [Next] to display STEP 4.

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05OTM-0140Eb

12.Select the appropriate check boxes in the [Optimization options] group box while
referring to the following table.
Note: Head optimization does not change the heads on modules with OF or G04 heads, nor can
it allocate these heads. These are special heads and if they are being used, then they
should be specified in their modules in the job before using AIMEX Multi Machine Optimizer.

Setting Description
Reallocate feeders If this option is selected, then feeders that have a variable
status can be moved or even deleted if they are not needed
during optimization.
If this option is not selected, then already existing feeders
cannot be moved or deleted and any newly required feeders
can be set in empty slots only.
Allocate parts with If this is selected, then any current positions for feeders are not
excessive changed and new feeders are only allocated to open places.
sequences to If this is not selected, then the current feeder positions and
multiple modules settings are completely ignored and all feeders are
redistributed.
Divide parts on Specify whether to reallocate parts on fixed feeders when
fixed feeders [Allocate parts with excessive sequences to multiple modules]
is selected.
When this is selected, parts on fixed feeders can be allocated
to other modules to reduce cycle time.
Use current feeder If this is selected, then any current positions for feeders are not
setup changed and new feeders are only allocated to open places.
If this is not selected, then the current feeder positions and
settings are completely ignored and all feeders are
redistributed. If there are variable status feeders that are not
being used in the current job in the feeder setup, these feeders
are removed.
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup.

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Setting Description
Nozzle station Specify the nozzle station nozzle arrangement method.
nozzle allocation • "Minimum" arranges for the minimum number nozzles
method required by the head.
• "Maximum" arranges for the maximum number of nozzles
allowable in the station.
Optimizer type This setting specifies the level of optimization to be performed.
• [Speed] performs optimization with a priority on achieving
a relatively fast cycle time and processing is performed
quickly.
• [Optimal] performs optimization with a priority on achieving
the fastest cycle time and processing takes longer.
• [Time Limit] performs processing the same as [Optimal] but
within a specified time limit.
Processing time This only displays if [Optimizer Type] is set to [Time Limit].
limit This specifies the time limit in minutes that the optimizer has
to complete processing.
Used feeder type Specify the whether of not reel holders are on the feeders.
• If set to [Reel holder], the optimizer positions feeders in the
feeder setup considering that the feeders have reel holders.
• If set to [Reel holder-E], the optimizer positions feeders in
the feeder setup considering that feeders have no reel
holders and a bucket type feeder pallet is used.

13.Click [Next].
When selecting a job which does not use a DX head in STEP 1, STEP 6 displays. (In
this case, go to STEP 14.)
When selecting a job which uses a DX head, STEP 5 displays.

05OTM-0226E

Setting Description

Optimize Auto-Tool The optimum auto-tool configuration is set taking into

configuration. account the quantity of auto-tools owned.

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Setting Description

Number of Auto- The configuration is optimized for the quantity of auto-tools

Tools owned entered.

Preferred multiple The auto-tool configuration is calculated in a way that more

set Auto-Tool. of the specified auto-tools are assigned into one module.

Optimize Auto-Tool The auto-tools that are used for production are set based on
to use. the auto-tool configuration specified in the job.

Processing time limit Specify the processing time limit for one round of
optimization for the auto-tools to be used.

14.Click [Next] to display STEP 6.

05OTM-0185Ea

15.Specify the maximum number of divided feeders.

Caution: A feeder may be duplicated fewer times than was specified.

• To specify the number of divided feeders for each part number, press the
[Settings] button. A dialog box for specifying the maximum number of divided
feeders for each part number will display.

05OTM-0183E

Item Explanation

PartNumber Displays the part number of the part assigned to the

machine for optimization.

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Item Explanation

Number of Displays the quantity of parts assigned to the

placements machine for optimization.

Number of Specify the maximum number of feeders that can

duplicated feeders be divided.

(Initially any previous values are displayed.)

a. Enter the required quantity into the [Number of Duplicated Feeders] column.
Caution: If "No" is specified for the [Allow Multiple Slots] setting in the part data for a part, feeders
are not duplicated for that part even if a quantity is specified in this step for that part number.

If you want to enter the same feeder quantity for all part numbers, click [Batch Input]
to display a dialog box for entering the value. Enter the desired value for all of the
part numbers and click [OK].

05OTM-0161E

b. Click [OK] to save the entered values.

• By clicking the [Settings] button in [Specify the number of divided feeders based
on the number of placements], a dialog box will display which will allow
specification of the quantity of divided feeders based on the number of
placements.

05OTM-0184E

a. Enter the number of placements for the feeder division quantity into the quantity
restriction area. Specify "0" to set no restrictions on the number of duplicated
feeders.

There is no duplication for up to 170 placements when performing settings as shown

in the above screen. Division is performed once for up to 350 placements. There is
no restriction for 351 placements or greater.

b. Click [OK] to save the entered values.

16.Click [Next] to display STEP 6 and perform dual production optimization. When
processing begins, the status is displayed in the upper part of the screen.

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05OTM-0141Eb

When processing is complete, the results and cycle times are displayed.

05OTM-0142Eb

17.Click [Save] to save the results of optimization and reflect them in the job.
Note: If this step is not performed, then none of the results of the optimization are reflected in the
job.

18.Click [Cancel] to close STEP 7 and exit AIMEX Multi Machine Optimizer.

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4.6 AIMEX Dual Production Optimizer

This is used for the AIMEX when performing dual lane production with different jobs in lanes
1 and 2, to create the optimal placement order of parts already assigned to the AIMEX and
the optimal feeder allocation for the two jobs.

After the jobs are created, jobs for both lanes are optimized.

05OTM-0143E

In order to use this software, jobs must satisfy the following condition.

• Jobs (one or two) that you wish to optimize must be in a state in which
production is possible.

4.6.1 Using AIMEX Dual Production Optimizer

1. Click the [Optimizer] tab in Director and then click the [AIMEX Dual Production
Optimizer] icon.

05OTM-0144E

The start screen of the AIMEX Dual Production Optimizer wizard is displayed.

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05OTM-0143E

Note: AIMEX Dual Production Optimizer can also be started by clicking the [Start] button and
selecting [Programs] - [Fuji Flexa] - [Optimizer] - [AIMEX Dual Production Optimizer].

2. Select either [Produce two different jobs.] or [Produce the Top and Bottom sides on the
same job.].

05OTM-0145E

3. Click the button in the [Lane1] group box to display a job list dialog box.

05OTM-0146

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4. Select the job to be used in the job list dialog box, and then click [Ok]. The job list dialog
box is then closed, and the selected job is displayed in the [Lane1] group box.
Note: If [Produce the Top and Bottom sides on the same job.] is selected, the selected job name
is displayed in [Lane2] group box.

5. Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Lane1] group box (Top or Bottom).

6. If [Produce two different jobs.] is selected, click the button in the [Lane2] group box.
A job list dialog box is displayed. Select the job to be used in the job list dialog box, and
then click [Ok]. The job list dialog box is then closed, and the selected job is displayed
in the [Lane2] group box.

7. If [Produce two different jobs.] is selected, select which panel side’s feeder setup is to
be used for that job from the drop-down list in the [Lane2] group box (Top or Bottom).

8. Click [Next] to display STEP 2.

05OTM-0147E

9. Select machines to be optimized in the list.

10.Click [Next] to display STEP 3.

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05OTM-0148E

11.Select the desired [Optimizer Option] settings. Refer to the table below for details
regarding the settings.

Setting Description
Reallocate feeders If this selected, feeder allocation is optimized.
If this is not selected, optimization is performed using the
currently specified feeder allocation.
Allocate parts with If this is selected, then any current positions for feeders are not
excessive changed and new feeders are only allocated to open places.
sequences to If this is not selected, then the current feeder positions and
multiple modules settings are completely ignored and all feeders are
redistributed.
Divide parts on Specify whether to reallocate parts on fixed feeders when
fixed feeders [Allocate parts with excessive sequences to multiple modules]
is selected.
When this is selected, parts on fixed feeders can be allocated
to other modules to reduce cycle time.
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
If this is not selected, then optimization is performed without
changing the nozzle setup.
Nozzle station Specify the nozzle station nozzle arrangement method.
nozzle allocation • "Minimum" arranges for the minimum number nozzles
method required by the head.
• "Maximum" arranges for the maximum number of nozzles
allowable in the station.

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Setting Description
Optimizer type This setting specifies the level of optimization to be performed.
• [Speed] performs optimization with a priority on achieving
a relatively fast cycle time and processing is performed
quickly.
• [Optimal] performs optimization with a priority on achieving
the fastest cycle time and processing takes longer.
• [Time Limit] performs processing the same as [Optimal] but
within a specified time limit.
Processing time This only displays if [Optimizer Type] is set to [Time Limit].
limit This specifies the time limit in minutes that the optimizer has
to complete processing.
Used feeder type Specify the whether of not reel holders are on the feeders.
• If set to [Reel holder], the optimizer positions feeders in the
feeder setup considering that the feeders have reel holders.
• If set to [Reel holder-E], the optimizer positions feeders in
the feeder setup considering that feeders have no reel
holders and a bucket type feeder pallet is used.

12.Click [Next] to display STEP 4 and perform dual production optimization. When
processing begins, the status is displayed in the upper part of the screen.

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When processing is complete, the results and cycle times are displayed.

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05OTM-0150E

Note: Click [Report] to display the the cycle times in a text editor such as Notepad.

13.Click [Save] to save the optimization results and reflect them in the job.
Note: If this step is not performed, then none of the results of the optimization are reflected in the
job.

14.Click [Cancel] to close STEP 4 and exit AIMEX Dual Production Optimizer.

Note: If optimization fails, click the [Error Log] button to display the content of any errors in a text
editor such as Notepad

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4.7 XPF Multi Machine Optimizer

When a line is comprised of multiple XPF machines, this software can be used to balance
the line between several XPF machines and optimize.

05OTM-0153E

The following job conditions are necessary to use this software.

• The line has already been selected in the job.

• A basic configuration has already been specified for the line. (Stage type,
revolver/multi-4 auto-tool use quantity, nozzles)
Caution: When optimizing the nozzles, they do not have to be specified.

• All marks used must be allocated to the machine.

• All parts to be placed must be allocated to at least one of the machines.

(Unassigned parts cannot be allocated with this software. The allocated parts
will be moved from the single machine to the other machines. )

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4.7.1 How to use XPF Multi Machine Optimizer

1. Click [Optimizer] at the Director icon bar and then select the [XPF Multi Machine
Optimizer] icon.

05OTM-0154E

The [XPF Multi Machine Optimizer] window displays.

05OTM-0153E

Note: Another way is to click [Start] - [All Programs], select [Fuji Flexa] - [Optimizer] and then click
[XPF Multi Machine Optimizer] to open the [XPF Multi Machine Optimizer] window.

2. Click [Next] at the [XPF Multi Machine Optimizer] window to display the [STEP1]
window.

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05OTM-0155E

3. Click the button in the [JOB] group box. A dialog box with a list of jobs displays.

05OTM-0137

4. Select the name of the job to optimize at the job list dialog box and then click [OK]. The
job list dialog box closes and the selected job displays in the [JOB] group box. The line
configuration of the selected job displays in the [Line Configuration] group box.

5. At the drop-down list to the left of the button in the [JOB] group box, select which
side of the job to use the feeder arrangement. ([Top] or [Bottom])

6. Click [Next] to display STEP2.

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7. Select the most suitable option at the [Optimizer Options] group box.

Settings Explanation

Optimize the revolver/ Select [Yes] to optimize the revolver/

multi-4 nozzle multi-4 nozzle arrangement, or [No] to
arrangement not optimize.

8. Click [Next] to display STEP3.

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9. Select the machine from the drop-down list at the top of the window.

10.Select feeders that can be used with the selected machine at the [Feeder Available] tab.

11.Select nozzles that can be used with the selected machine at the [Nozzle Available] tab.

12.When processing several machines, repeat steps 10 and 11 above for each machine.

13.Click [Next] to display STEP4.

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Caution: Once processing starts, the status of the optimization displays in the [Status] group box.

14.After processing ends, perform the tasks shown below according to the details of the
message shown in the [Status] group box.

a. If the message shows that line balancing was successful:

The cycle time for each job displays at the [Cycle Time] dialog box.

• To save the cycle time results to the job and exit, click [Save] and then [Exit]. To
exit without saving the cycle time results to the job, click [Exit] and then [Yes] at
the confirmation dialog box that displays.

b. If the message shows that optimization is being repeated until the user cancels:

• If you believe that the cycle time displayed in the graph is sufficient and want to
save the cycle time results to the job, click [Cancel], [OK], [Save] and then [Exit]
in that order.

• To improve the cycle time displayed in the graph, allow the process to continue.
However, the cycle time may still not improve.

• To exit without saving, select [Cancel], [OK], [Exit] and then [Yes] in that order.

c. If the message shows that line balancing failed:

• Click [Error log]. Check the details of the error that occurred during the
optimization process. After correcting the problem, optimize again.

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MEMO:

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5. Multi Line Multi Job Line Balancer

Multi Line Multi Job Line Balancer is a tool to create a new production plan so that jobs can
be produced efficiently with existing multiple lines.

5.1 Required Items

Items listed in this section are minimum requirements to run Multi Line Multi Job Line
Balancer. Do not use Multi Line Multi Job Line Balancer on computers with lower
specifications than these.

5.1.1 Operating system

• Microsoft Windows 7 Professional Edition SP1 64bit

• Microsoft Windows 7 Ultimate Edition SP1 64bit

• Microsoft Windows Server 2008 R2 Standard Edition SP1

• Microsoft Windows Server 2008 Standard Edition SP1, SP2

Caution: All 32-bit versions of Windows 7 are not supported.

5.1.2 Hardware
• Core i7 CPU (4 cores, 8 threads) or higher, 3 GB or more main memory

• Hard disk with 40 GB or more free space, floppy disk drive, CD/DVD-ROM drive,
and TCP/IP network interface

• Color monitor with resolution of 1024 x 768 or higher

• Windows-compatible mouse or equivalent pointing device

5.1.3 Supported machines

• NXT

• NXT II

• NXT IIc

• NXT III

• AIMEX

• AIMEX II

• AIMEX IIS

• XPF

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5.2 Using Multi Line Multi Job Line Balancer

1. Selecting the operation mode.

Select the operation mode to create a new production plan.

05OTM-0201E

Operation mode Description

Create a new Select this mode to create a new production plan.

production plan

Continue creating a Select this mode to load a production plan previously

previously saved created with this software and continue working on it.
production plan
The production time of the loaded production plan is
considered and then a new production plan is created.

Import a previously Select this mode to insert a job while a production plan
created production created with this software is being performed.
plan and insert a new
job A production plan previously created is imported, an insert
job and insert position is set, and then the production plan is
changed and recalculated.

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2. Specifying a production plan previously created.

When [Continue creating a previously saved production plan] or [Import a previously

created production plan and insert a new job] is selected, the following screen displays.

Select a plan you want to process from the list of the production plans previously created.

05OTM-0220E

Item Description

Date list Displays the list of creation dates of the previously created
production plans.

User name Displays the Fuji Flexa logged on user name who created
the selected production plan.

Line list Displays the line list of the selected production plan.

Display Report Displays the reports of the selected production plan.

3. Selecting lines.

Select the lines to be used for production. You can select multiple lines.

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Button Description

Add Adds lines selected in pane (a) to pane (b).

Note: If a multi production AIMEX line is selected in step a,
lane 1 and lane 2 are added separately in b.

Delete Deletes lines selected in pane (b).

Clear Clears all lines displayed in pane (b).

Settings Used to specify settings for lines displayed in pane b

(operating rate, waiting time before production can be
started, panel conveyance method, AB mode production)

Refer to section "Settings" below for details.

Import Saves the selected line configuration list to a csv file.

Save Imports a line configuration list saved previously.

Note:
• When selecting [Continue creating a previously saved production plan] in the
operation mode, only actions for "Settings" can be performed.
• When selecting [Import a previously created production plan and insert a new job] in
the operation mode, no actions can be performed in this step.

Settings

Specify settings for operating rate, waiting time before production can be started, panel
conveyance method, and AB mode production.
Note: When selecting [Continue creating a previously saved production plan] or [Import a
previously created production plan and insert a new job] in the operation mode, the results
of the production plan are automatically imported.

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Item Description

Line where settings Select the line for which you wish to specify settings.
are performed
Lines added in the step for adding production lines display in
a drop-down list.

Operating rate (%) Specify the operating rate of the selected line.

Waiting time before Specify the waiting time before production can be started.
production can be
started (minutes) For example, when there are lines which are started after
performing maintenance, optimization is performed
considering the maintenance time if the required time for
maintenance is entered.

In the example to the left, 2

lines at the bottom are
optimized so that the
production will start after 30
minutes of maintenance.

05OTM-0221

Conveyor type Specify the conveyor type of the selected line.

Enable AB mode Select this check box to enable AB mode for splitting the
production feeder pallet into 2 sides (left and right).

An AB Mode Multi Job Line Balancer license is required to

enable this option.

This cannot be enabled for XPF machines or multi

production AIMEX series machines.

Feeder usage ratio Select the feeder usage ratio from the drop-down list.
(side A : side B)
The feeder usage ratio definitions depend on the stage type.

Refer to the stage type tables in the "Feeder usage ratio

(Side A : Side B)" section below for details.

Divide left and right For single robot AIMEX series machines, divide feeder
within sides pallets within each side A and B.

Refer to the section below "Dividing feeder pallets" for

details.

Divide between side 1 For single robot AIMEX series machines, divide so that side
and side 2 1 operates as side A and side 2 operates as side B.

Refer to the section below "Dividing feeder pallets" for

details.

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Item Description

If the stage types are For single robot AIMEX series machines, if the stage types
different, divide left are different on each side, feeder pallets are divided left and
and right within sides right within sides; if the stage types are the same, side 1
operates as side A and side 2 operates as side B.

Feeder usage ratio (Side A : Side B)

Stage type: DP-20

Feeder usage ratio

Side A Side B
(Side A : Side B)
2:8 Slot 1.....4 Slot 5.....20
3:7 Slot 1.....6 Slot 7.....20
4:6 Slot 1.....8 Slot 9.....20
5:5 Slot 1...10 Slot 11...20
6:4 Slot 1...12 Slot 13...20
7:3 Slot 1...14 Slot 15...20
8:2 Slot 1...16 Slot 17...20

Stage type: DP245

Feeder usage ratio

Side A Side B
(Side A : Side B)
2:8 Slot 1.....9 Slot 10...45
3:7 Slot 1...14 Slot 15...45
4:6 Slot 1...18 Slot 19...45
5:5 Slot 1...23 Slot 24...45
6:4 Slot 1...27 Slot 28...45
7:3 Slot 1...32 Slot 33...45
8:2 Slot 1...36 Slot 37...45

Stage type: TU-M2

Feeder usage ratio

Side A Side B
(Side A : Side B)
2:8
3:7
4:6
5:5 TU-M(A) TU-M(B)
6:4
7:3
8:2

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Stage type: TU-LT (TU-LTC)

Note: Feeders are not allocated to the feeder section of TU-LT(TU-LTC).

Feeder usage ratio

(Side A : Side B) Side A Side B

2:8
3:7
4:6
5:5 TU-LT(A) TU-LT(B)
6:4
7:3
8:2

Dividing feeder pallets

Side 2 Side 2

Side A

Side B

Side 1 Side 1

Divide left and right within sides Divide between side 1 and side 2
05OTM-0173E

4. Selecting jobs to create a production plan.

Select all the jobs to be used in the production plan.

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Button Description

Add Displays the job selection screen. Select jobs to produce.

Also, specify the side of the panel for production.

Delete Deletes the specified jobs.

Open When selecting a job that is already open by another

software or computer, then that job cannot be loaded. Jobs
that cannot be opened are displayed with a red icon in the
job list.

In this case, close the opened job and click the [Open] button
to be able to load the job.

Once the job is loaded correctly, the icon changes to green.

Settings Specify the production quantity, priority, and target line in the
job setting dialog box.

Refer to " Settings " for details.

Import Saves the selected job list to a csv file.

Save Imports a job list saved previously.

Note: When [Import a previously created production plan and insert a new job] was selected in
the operation mode, actions mentioned above cannot be performed.

Settings

Specify the production quantity, priority, and target line in the job setting dialog box.

If multiple jobs are selected in the job list, values will only be changed for items for which
the check box is selected.

05OTM-0205E

Item Description

Production Quantity Enter the production quantity.

Priority Specify the priority.

Jobs are allocated in order from the highest priority.

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Item Description

Target Line Select this check box if you want to specify lines to which to
allocate the jobs.

Multiple lines can be selected. When multiple lines are

selected, optimization is performed so that jobs are
allocated to the selected lines.

5. Specifying the production condition.

Specify the production condition such as the changeover method.

05OTM-0206E

Item Description

Changeover method Specify the changeover method.

[Create common feeder setups and reduce changeover.]:

Shared feeder allocations are created to reduce the number

of feeders changed during changeover.

Feeders are individually exchanged during changeover.

[Create common feeder setups and use batch feeder

changeover.]:

Feeder allocations are shared as much as possible.

Feeders that cannot be shared are batch exchanged using

feeder pallets on all machines.

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Item Description

Feeder allocation When continuing to create a plan that was previously

settings created, the last job of the previous plan is taken as the
reference and the feeder allocation is considered.
Note: This setting is available when [Create common
feeder setups and reduce changeover.] is selected
for [Changeover method].

[Consider the allocation of all feeders.]:

Processing is performed considering the allocation of all

feeders for the reference job.

[Consider the allocation of "Reserved" and "Fixed" feeders

only.]

Processing is performed considering only the feeders with

which the status is set to [Reserved] or [Fixed] for the
reference job.

Allocation of top and Select this check box to allocate the top and bottom sides to
bottom sides of same the same line.
job

Work time settings [Feeder exchange time (seconds)]:

Specify the time required for one person to change one

feeder.

[Nozzle exchange time (seconds)]:

Specify the time required for one person to change one

nozzle.

[Number of operators per line]:

Specify the number of people performing changeover at the

same time.

Note: For [Feeder allocation settings]

• When [Create a new production plan] is selected in the operation mode, the model
default values of the machine is used for the reference feeder allocation. Moreover,
optimization is performed considering only feeders with which the status is set to
reserved or fixed.
• When [Import a previously created production plan and insert a new job] is selected
in the operation mode, the reference feeder allocation is immediately before the job
at the insert position. However, if [Do not change any of the jobs. Only decide if the
job can be inserted without changes or not.] is selected, feeder allocation is not
changed for all jobs.

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6. Specifying other items.

05OTM-0207E

Item Description

Part data reference [Acquire part data from server.]:

location
To use this option, part data in all jobs to process must be
saved in the server.

[Specify job from which to acquire part data.]:

To use this option, part data in all jobs to process must be in the
specified job.

Allocating parts to [Allocate all the parts in jobs.]:

machines
All parts in the job are allocated.

Any parts you do not want to place must be assigned with skips
beforehand.

[Allocate only parts which are already allocated to machines in

the current line configuration.]:

Only parts allocated to the machine are allocated.

When there are no line settings in the job and parts have not
been allocated, no parts are allocated.

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Item Description

Optimizer options [Optimize the position of nozzles in the nozzle station.]:

Nozzle allocation for the nozzle station is optimized.

[Use the same nozzle setup for all jobs.]:

When the nozzle allocation is optimized, the same nozzle setup

is used for all of the jobs.

[Allocate parts with excessive sequences to multiple modules.]:

Duplicate feeders to several modules for parts with many

placements.

Optimization level [Complete in the shortest time without adjusting the balance
settings between lines.]:

Jobs are allocated to the lines in the shortest processing time.

Use this mode if you want to shorten the processing time.

[Adjust the balance between lines.]:

Jobs are allocated to the lines while adjusting so that the

balance in production time between lines is consistent. Use this
mode if you want to acquire allocation results for optimized
jobs.

[Continue processing until [Cancel] is clicked.]:

After allocating jobs while adjusting the balance in production

time between lines, cycle time improvements are repeated for
each line until this processing is canceled.

Use this mode if you want to acquire a very accurate cycle time
for each line.

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7. Selecting the insertion method.

The screen to set the insertion method is displayed only when [Import a previously created
production plan and insert a new job] is selected in the operation mode.

Specify jobs to insert and insertion positions. Select the insertion position with the graph.

05OTM-0208E

Gray: Waiting time before production can Red: Changeover time

be started (minutes) (minutes)

Blue: Production time for jobs (minutes) Yellow: Selected job

By double-clicking the graph, detailed information for

the target job is displayed.

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Item Description

Select the insertion [Change all jobs in the selected line which come after the
method inserted job.]:

Including inserted jobs, all jobs after the insertion position are
allocated and the feeder allocation is shared.

[Allow changes to the inserted job only]:

Feeder allocation is shared so that the changeover amount is

lower for the inserted jobs from jobs before they are inserted.

Use this mode when you do not want change already

planned jobs.

[Do not change any of the jobs. Only decide if the job can be
inserted without changes or not.]:

The cycle time and changeover time are calculated and

reports are created without changing all jobs.

Use this method if you do not want to change jobs both

already planned and to be inserted.

The line name of the inserted job must be the same as the
line to which to insert the job.

Select the job to Import The job selection screen displays by clicking
insert the [Import] button. Select a job to insert.

Multiple jobs cannot be selected.

Top/bottom Specify the panel side.

Both sides cannot be selected.

Settings Specify the production quantity in the job

setting dialog box.

Refer to " 4. Selecting jobs to create a

production plan. ", " Settings " for details.

Target position job Displays the job name selected in the graph of the production
plan.

The job is inserted immediately before the selected job.

Note: For AB mode production lines, or multi production
AIMEX series machines, jobs cannot be newly
inserted into the line.

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8. Optimizing.

After completing optimization, you can display and output reports, output logs, and save
jobs.

Also, you can retry optimization by going back to previous screens and changing the
settings without saving the results. Once you save the results, you cannot go back to
previous screens.

05OTM-0210E

Button Description

Display Report Displays created reports.

Outputs Report Outputs created reports.

Reports are output to XML files and CSV files.

Output Log Outputs an error log.

Save Saves the job.

By double-clicking the graph, detailed information for the target

job is displayed.

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5.3 Reports
There are an overall report and detailed reports available from Multi Line Multi Job Line
Balancer.

In the overall report, links to the job allocation results, production time, and detailed reports
of each line are displayed. Detailed reports of each line can be displayed by clicking a link.

In detailed reports, detailed information such as cycle time and changeover of each job is
displayed.

5.3.1 Overall report

Report header
The processing date and user name are displayed in the report header.

05OTM-0211

Item Description

Date Displays the date when Multi Line Multi Job Line Balancer processing was
completed.

Time Displays the time when Multi Line Multi Job Line Balancer processing was
completed.

User Displays the Fuji Flexa logged on user name when Multi Line Multi Job Line
Name Balancer was performed.

Overview
A graph showing the production time of each line is displayed.

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Product Time
Production time of each line is displayed.

05OTM-0213

Item Description

Line Name Displays the entered line name.

Production Time (min.) Displays the overall production time for each line. The
overall production time is the total of the production time
and changeover time of all the jobs allocated to the line.

Availability (%) Displays the operation rate of the line.

Assign Job List

The list of the jobs allocated to each line is displayed.
Note: The assign job list is displayed in the format of "job name [revision] / panel side".

05OTM-0214

Line Report
Links to detailed reports of each line are displayed. By clicking a link, detailed reports for
that line are displayed.

For multi production AIMEX series machines, detailed reports are displayed for each lane.

05OTM-0215a

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5.3.2 Detailed Report

Timing Report
Cycle times and changeover times of optimized jobs are displayed in the production order.

05OTM-0216a

Item Description

Job Name Displays the job name [revision] and panel side.

Cycle Time (sec.) Displays the cycle time for one panel.

Production Time (min.) Displays the production time.

Production time = Cycle time (seconds) x Production

quantity / Operation rate of the line (%)

Changeover Time (min.) Displays the time for changeover.

Group Displays the group for the job.

Changeover is not necessary for jobs within the same

group.
Note: Only lines at which AB mode production is
performed display.

Changeover Wait Time Report

Displays the cycle time and changeover time for each group.
Note: Only lines at which AB mode production is performed display.

05OTM-0223

Field Description

Group Displays the name of the group.

Production Time (min.) Displays the total "production time" for all the jobs within
the same group.

Changeover Time (min.) Displays the total "changeover time" for all the jobs within
the same group.

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Group
Displays the list of jobs which belong to the same group. Changeover is not necessary for
jobs in the same group and production is possible without changing the nozzle or feeder
allocation.

Nozzle Changer Setup Report and Feeder Setup Report are displayed for each group.
However, for Nozzle Changer Setup Reports for lines at which AB mode production is
performed, the same report is created for all groups.

05OTM-0217

Nozzle Changer Setup Report

Nozzle allocations shared for jobs in a group are displayed for each nozzle station.

05OTM-0218a

Item Description

No Displays the nozzle station socket number.

Result Compares the nozzle allocation to the nozzle allocation before

changeover and indicates whether nozzles need to be added,
removed, or exchanged. Add: Add nozzles Delete: Remove nozzles
Change: Change nozzles

Name Displays the name of the nozzle.

Spec Name Displays the specification name for the nozzle.

Diameter Displays the diameter of the nozzle.

Size X Displays the X-direction size of the nozzle.

Size Y Displays the Y-direction size of the nozzle.

Head Type Displays the specification type for the placing head that can use that
nozzle.

Length Displays the length of the nozzle.

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Feeder Setup Report

Feeder allocations shared for jobs in a group are displayed for each machine.

05OTM-0219a

Item Description

Position Displays the slot number of the feeder.

Result Compares the feeder allocation to the feeder allocation before

changeover and indicates whether feeders need to be added,
removed, or exchanged. Add: Add feeders Delete: Remove feeders
Change: Change feeders

Part number Displays the part number.

Part Comment Displays the part comment.

Type Displays the feeder type.

Width [mm] Displays the width of the reel.

Qty Displays the placing quantity per panel for that position.

Side Displays the side of the feeder pallet to be used.

A: side A

B: side B
Note: Only lines at which AB mode production is performed display.

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6. Multi Machine Multi Job Line

Balancer
Multi Machine Multi Job Line Balancer is software that creates feeder arrangements for
multiple jobs for multiple lines configured with multiple machine types in order to minimize
feeder changeovers and it also optimizes the placing order.

Multi Machine Multi Job Line Balancer is an option item. An NXT Multi Job Line Balancer
or AIMEX Multi Job Line Balancer license is required to use this software.

05OTM-0242E

The following has to be completed/fulfilled before using this software.

• When using part data on the server, make sure that the data exists on the server
before optimizing.

• When using part data from the job used for the line and feeder setup, copy all
the part data to this job.

• Have all of the necessary parts assigned in each job beforehand. (Unassigned
parts cannot be allocated with this software. Allocated parts can be moved
between machines.)

6.1 Supported machines

• NXT

• AIMEX

• AIM

• XPF

• XP141, XP142, XP143, XP241, XP242, XP243, XP341

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6.2 Using Multi Machine Multi Job Line Balancer

1. Click the [Multi Job Line Balancer] tab in Director and then click the [Multi Machine Multi
Job Line Balancer] icon.

05OTM-0241E

The start screen of the Multi Machine Multi Job Line Balancer wizard is displayed.

05OTM-0242E

Note: Multi Job Line Balancer can also be started by clicking the [Start] button and selecting
[Programs] - [Fuji Flexa] - [MultiJob Line Balancer] - [Multi Machine MultiJob LineBalancer].

2. Click [Next] in the Multi Machine Multi Job Line Balancer wizard to display STEP 1.

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Step 1. Select jobs

05OTM-0243E

Setting Description

Name Displays the name of the job.

Revision Displays the revision of the job.

Face Displays the side of the panel for production for the job.
Top: The top side is to be produced.
Bottom: The bottom side is to be produced.
Top/Bottom: Both the top and bottom are to be produced.

Group Displays the group name for the job.

Production Quantity Displays the quantity of panels to be produced.

Prioritizing Displays the side that is to be produced first (top or bottom).

Production
When optimizing the production order in STEP 4, this setting
is checked and the production order is determined.
Top:The top side is to be produced before the bottom.
Bottom:The bottom side is to be produced before the top.
Either: A specific order for top or bottom is not specified.

3. Click [Add] to display a job selection dialog box.

05OTM-0244

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4. Select the jobs to be used in the job selection dialog box.

Note: To select multiple jobs, click the jobs while holding down the [CTRL] key.

5. After completing job selection at the job selection dialog box, click [OK].
The job selection dialog box is then closed and the [Select panel side] dialog box is
displayed.

05OTM-0015Ea

6. In the [Select panel side] dialog box, select the panel side for the selected jobs from
[Top], [Bottom] or [Top / Bottom], and then click [OK].
The [Select panel side] dialog box is then closed, and the selected jobs are added to the
list.

05OTM-0245E

7. Repeat steps 3 to 6 if adding more jobs to the list.

Note: To delete a job from the list, select it and then click [Delete]. To delete all jobs from the list,
click [Clear].

8. When changing the side for which the job is performed, the production quantity, or the
production priority order, select and right click the applicable job and select the
appropriate option from the menu.

• Selecting the [Enter the production quantity] will display the [Production
Quantity] dialog box.

Enter the production quantity and click [OK].

9. When finished adding jobs, click [Next] to display STEP 2.

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Step 2. Specify changeover settings 1

05OTM-0246E

10.Click the button in the [Job used for line or feeder setup] group box to display a job
list dialog box.

05OTM-0244

11.Select the name of the job to use as the line and feeder setup at the job list dialog box,
and then click [OK].
The job list dialog box is then closed, and the selected job is displayed in the [Job used
for line or feeder setup] group box.

12.Select which panel side’s feeder setup is to be used for that job from the drop-down list
in the [Job used for line or feeder setup] group box.

13.Select the following option in the [Job used for line or feeder setup] group box if required.

Setting Description
Acquire part data Normally, part data is acquired from the part data server.
from this job
instead of the However, if this check box is selected, the part data from the job
server. selected in [Job used for line or feeder setup] is used.
Caution: When this setting is selected, it is necessary for the
specified job to have all of the part data from all of the
jobs selected in STEP 1.

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14.Select the appropriate option in the [Feeder allocation settings] group box.

Setting Description

Consider the All of the variable status feeders for the job in the [Job used
allocation of all for line and feeder setup] setting are not moved from their
feeders positions as much as possible. (Feeders will be added if
necessary for other jobs.)
Fixed and reserved feeder positions from this job cannot be
altered.

Consider the Fixed and reserved feeder positions for the job in the [Job
allocation of used for line and feeder setup] setting cannot be altered.
Reserved and Fixed However, variable status feeders can be altered freely.
feeders only

15.Select the appropriate option in the [Settings] group box.

Setting Description
Group jobs for A common feeder allocation for multiple jobs is created and the
batch jobs are grouped. There are times when multiple groups are
changeover. possible. In this case, changeover between groups occurs but
the feeder allocation is not common between groups.
Reduce feeder A common feeder allocation for multiple jobs is created and the
changeover jobs are grouped. There are times when multiple groups are
times. possible. In this case, changeover between groups occurs.
However, the feeder allocation of the previous group is
considered.
As a result, a feeder allocation is created that reduces the
changeover of the feeder allocation as much as possible.
Compared to [Group jobs for batch changeover], the number of
feeder changeovers is reduced. However, it is difficult to
balance the cycle time.

16.Click [Next] to display STEP 3.

Step 3. Specify changeover settings 2

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17.Enter suitable values for each parameter in the [Changeover parameters - changeover
time (seconds)] group box and [Changeover parameters] group box.

Setting Description

Feeder changeover Specify the time required for one person to change one
(seconds) feeder.

Nozzle changeover Specify the time required for one person to change one
(seconds) nozzle.

Persons Specify the number of people performing changeover at the

same time.
Caution: If "1" is specified, calculation will be performed with
one changeover person for current production and
one changeover person for the next production.

18.When specifying a module for which changeover is not performed, select the module
from the [Select modules for which changeover is not performed] group box.
This cannot be selected when specifying settings for machines other than NXT and
AIMEX.
Note: Specifying a module for which changeover is not performed improves the efficiency rate.

Setting Description
In cases where a Select in cases where changeover is to be permitted on a
feeder cannot be module for which changeover is not performed has been
allocated, allow for specified when it is not possible to arrange all feeders.
allocation even if it
means canceling the
locked in
changeover.
Select all Selects the check boxes for all modules.

19.Click [Next] to display STEP 4.

Step 4. Specify the production order and panel conveyance method

05OTM-0248E

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20.Change the production order if necessary. The production order can be changed
automatically or manually.

Automatic method
a. Click the [Optimize] button if you wish to optimize the production order. A dialog box
displays with an optimization option choice.

05OTM-0020E

Option Description
Optimize jobs in order to This optimizes the order to minimize the amount of
reduce feeder change changeover.
times
Order by production The jobs are ordered based on the quantity of
quantity panels to be produced for each job.

b. Select the desired optimization option in the dialog box and then click [OK]. The
dialog box closes and the production order is changed automatically.

Manual method
a. Select jobs from the list and use the [Up] and [Down] buttons to move them.

b. Specify the panel transport method for each job by right-clicking the desired job and
selecting the appropriate option from the menu.

05OTM-0249E

Panel conveyance Description

menu items
Single Lane Specify this when producing a job at a single lane.
Dual Lane / Lane1 Specify this when producing a job at lane 1 of a
dual lane machine.

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Panel conveyance Description

menu items
Dual Lane / Lane2 Specify this when producing a job at lane 2 of a
dual lane machine.

21.Click [Next] to display STEP 5.

Step 5. Specify optimization settings

05OTM-0250E

22.Specify the settings you want to use.

Setting Description
Allocate parts with If this is selected, parts with many placements will be set in
excessive multiple feeders and placed on multiple modules if possible.
sequences to
multiple modules
Divide parts on fixed When [Allocate parts with excessive sequences to multiple
feeder modules] is selected, you can specify whether to reallocate
parts on fixed feeders.
If this option is selected, parts on fixed feeders can be
allocated to other modules to reduce cycle time.
Optimize nozzle This specifies whether the nozzle allocation should be
station optimized or not.
If this is selected, the nozzles in the nozzle station will be
changed to be "optimized" for production.
Caution: This is not supported for AIM, XP-241, XP-242, and
XP-243 machines.

If this is not selected, then optimization is performed without

changing the nozzle setup. (The job allocation specified in
step 2 is used.)

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Setting Description
Used feeder type Specify whether or not reel holders are on the feeders.
If set to "Reel holder", the optimizer positions feeders in the
feeder setup considering that the feeders have reel holders.
If this is set to "Reel holder-E", the optimizer positions feeders
in the feeder setup considering that feeders have no reel
holders and a bucket type feeder pallet is used.
Check Part Sensor Specify whether parts that are to have a part check performed
are allocated considering the part sensor setting.
If this is set to "Must Use", all parts that are to have a part
check are allocated to heads that have part sensors.
If this is set to "Do not consider", parts are allocated with the
emphasis on balancing the line without considering which
heads have part sensors.
Caution: There will be cases in which parts that are to have a
part check are allocated to a head without a parts
sensor and cases in which parts that are not to have a
parts check are allocated to a head with a parts
sensor.

Tray Direction Specify whether to adjust the tray direction when performing
optimization.
If this is set to "Auto", the tray direction is automatically
adjusted.
If this is set to "0 deg", the tray direction is always 0 degrees.
If this is set to "90 deg", the tray direction is always 90
degrees.
If this is set to "180 deg", the tray direction is always 180
degrees.
If this is set to "270 deg", the tray direction is always 270
degrees.

23.Click [Next] to display STEP 6.

Step 6. Specify nozzle and feeder settings

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24.Specify the feeders and nozzles that can be used.

Select the machine type and specify settings for each of the machine types.

Changes to shared nozzles and feeders (orange background) are reflected between
machine types.

• Select the nozzles that can be used in the [Nozzle Available] tab. When there is
a limit on the quantity available, select the nozzle and then right-click and select
the command for specifying the quantity of nozzles.

• Select the feeders that can be used in the [Feeder Available] tab. When there is
a limit on the quantity available, select the feeder and then right-click and select
[Specify the number of feeders].

25.Click [Next] to display STEP 7.

Step 7. Preparation completed

05OTM-0252E

26.If all the current settings are correct, click [Next] to display STEP 8 and perform line
balancing.

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Step 8. Run

05OTM-0253E

Note: When processing begins, the status is displayed in the [Status] group box.

27.When processing is complete, perform one of the following depending on the content of
the message in the [Status] group box.

a. If the message states “Line balance successful”

If the [Cycle Time] dialog box is displayed, the cycle time for each job is shown.
Details of the optimization processing result are output to the report.

05OTM-0254E

• Click [Display Report] to refer to the report. Refer to section "6.3 Reading the
optimization report" for a view of the report.
Click [Save Report] to save the report.

• Click [Save] followed by [Exit] to save the processing content and complete the
line balancing procedure. Alternatively, to exit line balancing without saving the
processing content, click [Exit] and then click [OK] in the confirmation box that
displays.

STEP 8 is then closed.

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b. If the message states “Repeating optimization until cancelled...”

The user is responsible for deciding when to terminate the procedure.

• If satisfied with the cycle time displayed in the graph and wishing to save the
processing content and exit line balancing, click [Cancel], [OK], [Save] and
[Finish] in this order.

• Continue processing if not satisfied with the cycle time. It should be noted,
however, that the cycle time may not improve even when continuing. To exit
without saving the processing content, click [Cancel], [OK], [Finish] and [Yes] in
this order.

STEP 8 is then closed.

c. If the message states "Unable to balance the line"

• Click [Error Log] to display the errors from the message group box in a text editor
such as Notepad. Checks the contents of any errors.

Click [Exit] after the checking the content of errors.

STEP 8 is then closed.

Correct any errors using Job Builder and then run Multi Machine Multi Job Line
Balancer again.

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6.3 Reading the optimization report

The optimization results from Multi Machine Multi Job Line Balancer are displayed in the
following report.

(a)

(b)

(c)

(d)
(e)
(f)

(g)

(h)

05OTM-0255

(a) Title
(b) Report header

Item Meaning
Date Displays the date when optimization processing was
completed without any errors.
Time Displays the time when optimization processing was
completed without any errors.
User Name Displays the Fuji Flexa logged on user name when
optimization processing was performed.

(c) Timing report

This section of the report displays the optimized cycle time and changeover time for
the jobs in the order they are to be produced.

Item Description
Job Name Displays the name of the job.
Cycle Time (sec.) Displays the cycle time for one panel.
Production Time (min.) This displays the production time which is "Cycle Time" x
"number of panels to produce".
Change Over Time Displays the time for changeover.
(min.)

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(d) Group name

Displays the group name for the jobs. The "0" part of the name changes for each
group because this section is broken into groups.

(e) Job name

The names of jobs in the same group are displayed in a list. It is possible to perform
production between the jobs within this list without changing the feeder allocation.

Format: "Job Name" / "Panel Side" ("Top", "Bottom")

(f) Model name

Displays the model name of the machine in the jobs. When there are multiple
machines in the line, a nozzle setup report and feeder setup report are displayed for
each machine model.

(g) Nozzle changer setup report

Item Description
No Displays the nozzle station socket number.
Result Compares the nozzle allocation to the nozzle allocation for the
[Job used for line or feeder setup] job (from STEP2) and indicates
whethexr nozzles need to be added, removed, or exchanged.
Add: Add the nozzle.
Delete: Remove the nozzle.
Change: Exchange the nozzle.
Name Displays the name of the nozzle.
Spec Name Displays the specification name for the nozzle.
Diameter Displays the diameter of the nozzle.
Size X Displays the X-direction size of the nozzle.
Size Y Displays the Y-direction size of the nozzle.
Head Type Displays the specification type for the placing head that can use
that nozzle.
Length Displays the length of the nozzle.

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(h) Feeder setup report

Item Description
Position Displays the stage number and the slot number of the feeder.
Result Compares the feeder allocation to the feeder allocation for the
[Job used for line or feeder setup] job (from STEP 2) and
indicates whether feeders need to be added, removed, or
exchanged.
Add: Add the feeder.
Delete:Remove the feeder.
Change:Exchange the feeder.
Part Number Displays the part number for the part.
Part Displays the part comment for the part.
Comment
Type Displays the feeder type.
Width [mm] Displays the width of the reel.
Feeder Name Displays the name of the feeder.
Qty Displays the placing quantity per panel for that position.

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Fuji Flexa Optimization Manual

Software Version V6.18.0

Management No. OTM-FLX-2.5E

Notes

Issued on March 2017

FUJI Machine Mfg. Co., Ltd.

19 Chausuyama, Yamamachi, Chiryu,
Aichi Prefecture, 472-8686 Japan

 2017 FUJI MACHINE MFG. CO., LTD. All Rights Reserved.

Printed in Japan
This manual is printed on recycled paper.