Logically Centralized Scrap Management in Production Planning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current inventory and production management systems lack comprehensive scrap management capabilities, particularly in calculating and planning for different types of scrap, which can lead to inaccurate material requirements and increased costs due to the lack of integration of activity, fixed resource, and component scrap calculations.
Innovation Solution
The system instantiates a planning business object using production model data to calculate scrap requirements by adding activity yield and fixed resource scrap to generate component quantities, which are then multiplied by a component scrap ratio to determine additional requirements, and performs scrap checks to ensure accurate unit conversions and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If comprehensive scrap management is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system segments scrap management into three distinct types: assembly scrap, component scrap, and operation scrap. Each type is calculated and managed separately through dedicated planning runs, allowing precise control over each scrap category while maintaining overall system accuracy without excessive complexity.
Solution Approach 2:
The planning run system serves multiple functions: it calculates assembly scrap, component scrap, and operation scrap within a single integrated framework. This multi-functional approach enables comprehensive scrap management while avoiding the need for separate complex systems for each scrap type.
2Manufacturing precision
If assembly scrap increases order quantity, then manufacturing precision is improved, but loss of substance increases
Solution Approach 1:
The system performs preliminary scrap calculations during the planning phase before actual production. By calculating assembly scrap, component scrap, and operation scrap in advance and adjusting order quantities accordingly, the system ensures accurate material requirements are established before production begins, preventing both shortages and excesses.
Solution Approach 2:
The planning run incorporates feedback loops where scrap calculations from previous operations inform subsequent material requirements. The system continuously adjusts order quantities based on calculated scrap quantities, ensuring that material requirements accurately reflect actual production needs while minimizing waste.
Data Source
AI summary
The present disclosure relates to methods, systems, and software for processing or otherwise managing scrap information in a business application. For example, the software can instantiate a planning business object using production model data for production activities. The business object data and scrap information may be used to calculate requirements for a production planning model. The calculations may include adding an activity yield to activity scrap and fixed resource scrap to generate a component quantity. The component quantity can be multiplied by a component scrap ratio to generate additional component requirements. The component quantity may be added to the additional component requirements to determine a total quantity.