Dual Lane (Parallel Stations) in React: Configuration and Operation

1.Purpose of the Feature

Parallel stations in React allow multiple physical machines or work areas to operate simultaneously at the same process step. This enables higher throughput, flexible product routing, and better cycle time balancing across production lines. React supports parallel stations for scenarios such as dual-lane SMT lines, multiple testers, or conveyors running different products or work orders in parallel.

2. How Dual Lane Works

• Definition: A parallel station is a physical station configured to run concurrently with one or more other stations at the same process step. Each station processes units independently, but their outputs are logically grouped for throughput and downtime analysis
• Product Routing: Parallel stations can run:
  • Same part number (to increase throughput or match cycle time).
  • Different part numbers or work orders (dual-lane or split-line scenarios)
• Data Aggregation:
  • When multiple products or work orders are processed in parallel, the system must distinguish which units belong to which product via program name.
  • Without explicit attribution, throughput data can become conflated, leading to inaccurate metrics for yield, cycle time, and OEE

3. How is throughput and cycle time calculated?

When two products are running on parallel stations, they may have 2 different expected Cycle Times. React handles cycle time as follows:

• Throughput: The system combines the outputs of both parallel stations to calculate overall line throughput.
• Cycle Time Deviation: The product with the largest cycle time is used as the effective cycle time for the line. This ensures that the slowest pacemaker station determines the downtime for the process step

4. Configuration or Setup Requirements

To enable and configure parallel stations in React:

1. Factory Map
   • Mark each physical station as a separate entity in the factory map.
   • Set the "Parallel Operation" property to True for all stations that should run in parallel
   • Avoid mapping parallel stations as duplicates (i.e., do not use multiple aliases for a single physical station)

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2. React Configuration Assignment:
   • Assign the appropriate configuration profile (e.g., "Sprint 1 Testing") to each line or group of lines where parallel operation is required.
   • Ensure all relevant boolean flags for parallel operation are set to True in the configuration
3. Product Map
   • For each product add the attribute 'consider_for_parallel_station' and set it to 'true'.
   • (Not pictured) Add another attribute called 'program_name' with the value populated in by the machine.

     • Practical example: "SMT Top" is running Product A and "SMT Bottom" is running Product B, each station must report its throughput with a clear identifier (e.g., program name = "ProductA_Top", "ProductB_Bottom"). Note, regex would also be accepted for example "*_Top"

       

5. Example Setup for Dual-Lane SMT Line

• Step 1: Identify Line 1 has parallel stations.
• Step 2: In Factory Map, set the line property “Parallel Operation = True.”
• Step 3: Identify Product A and Product B runs in parallel on Line 1.
• Step 4: In Product Map, set the step property "consider_for_parallel_station = true". 
  • For example, Product A “SMT Top,” and Product B step, “SMT Bottom".
• Step 5: Set cycle times for both in Product Map; system uses the slower station’s cycle time for line-level calculations.
• Step 6: In React, create and assign the config to the SMT line.
• Step 7: Validate by running both products and reviewing analytics.

6. Best Practices

• Always map each parallel station as a unique physical entity.
• Regularly review cycle time and throughput data to ensure the configuration matches operational reality.

7. Example Use Cases

• Dual-Lane SMT Line: Top and bottom lanes run in parallel, each as a separate station but part of the same process step
• Multiple Testers: Several testers operate in parallel to keep up with upstream process cycle time, with the slowest tester’s cycle time defining the line’s effective cycle time
• Parallel Conveyors: Two conveyors run different part numbers or work orders in parallel, each tracked separately but aggregated for line-level reporting