Manufacturing Cell Control System for Delay Redistribution
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Solution Overview
Problem
In manufacturing systems with multiple cells, operational delays due to machine breakdowns or defects can lead to reduced productivity and efficiency, causing waiting times and reduced production speed, as cells with spare time cannot effectively compensate for delayed operations.
Innovation Solution
A manufacturing management apparatus that connects production planning and cell control systems to identify and redistribute operations by transferring machines and operations between cells, allowing cells with spare time to assist cells with delays, thereby optimizing production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manufacturing cells operate independently according to the manufacturing plan, then each cell can perform its designated operations, but delays in one cell cause waiting times in other cells and reduce overall productivity
Solution Approach 1:
The patent merges operations from multiple manufacturing cells by transferring machines between cells. When a delay is detected in one cell, operations are transferred from cells with spare capacity to the delayed cell, combining resources to maintain production speed and eliminate waiting times.
Solution Approach 2:
The system dynamically adjusts cell operations in real-time based on actual progress. The control device monitors operation status and dynamically transfers machines between cells based on spare capacity and delay conditions, making the system flexible rather than rigid.
2Ease of manufacture
If manufacturing machines are fixed in specific cells, then each cell has dedicated resources, but delays cannot be compensated by other cells leading to reduced operation efficiency
Solution Approach 1:
Manufacturing machines are designed with multi-functionality to operate in different cells. A machine can be transferred from one cell to another and perform operations in both locations, making the machine universal rather than cell-specific. This enables resource sharing and delay compensation while maintaining operational simplicity.
3Productivity
If operations are redistributed in real-time based on actual progress, then delays can be corrected and productivity improved, but system complexity increases due to real-time monitoring and coordination
Solution Approach 1:
The control device implements feedback by continuously monitoring actual operation progress and comparing it with the manufacturing plan. When delays are detected, the system automatically adjusts operations by transferring machines between cells, creating a closed-loop control system that corrects deviations in real-time.
Solution Approach 2:
The system performs self-service by automatically detecting delays and executing corrective actions without external intervention. The control device autonomously identifies which cells have spare capacity and transfers machines accordingly, making the system self-regulating and reducing the need for complex external coordination.
Data Source
AI summary
A cell control apparatus controls a plurality of manufacturing cells each including a manufacturing machine. The cell control apparatus comprises an operation extraction part configured to extract a transferable operation which can be performed by a manufacturing cell having operation time to spare among operations of a manufacturing cell having delay in operation. The cell control apparatus commands the manufacturing cell having delay in operation to stop at least a part of operations in the transferable operation and commands the manufacturing cell having the operation time to spare to perform the at least the part of the operations.