Controller for Aggregating Orders in Pre-Print Manufacturing
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Solution Overview
Problem
Current paper and box manufacturing systems lack efficient methods for generating control plans that optimize order aggregation, waste reduction, and process efficiency across various manufacturing phases, leading to inefficiencies and potential improper combinations of orders.
Innovation Solution
A system comprising a controller that aggregates orders, filters based on criteria like deadlines and manufacturing capabilities, and generates control plans to optimize order processing, reduce waste, and align orders with available resources, including the ability to split orders and adjust for optimal paper width, while providing instructions for printers and sheet formation systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple orders are aggregated into a single control plan, then productivity and resource utilization improve, but the complexity of managing and coordinating these orders increases
Solution Approach 1:
The control plan is segmented into multiple lanes, with each lane independently managing a subset of orders. This allows the system to handle multiple orders simultaneously while maintaining manageable complexity within each lane. The segmentation enables parallel processing of orders without requiring coordination across the entire order set.
Solution Approach 2:
The controller acts as an intermediary that receives orders from multiple sources, processes them through filtering and aggregation logic, and distributes them to appropriate lanes. This intermediary layer manages the complexity by abstracting the coordination details from individual order processing, allowing multiple orders to be handled efficiently through a centralized management point.
2Manufacturing precision
If orders are filtered based on multiple criteria (deadlines, manufacturing capabilities, etc.), then manufacturing precision and resource alignment improve, but the time required to generate control plans increases
Solution Approach 1:
Orders are pre-filtered and pre-processed before being added to control plans. The system maintains a pool of pre-evaluated orders that have already been checked against manufacturing capabilities and other criteria. This preliminary action reduces the time required during control plan generation, as the filtering work has been done in advance.
Solution Approach 2:
The system uses feedback from manufacturing system status and order characteristics to dynamically adjust filtering criteria and selection priorities. This allows the controller to optimize the balance between precision and speed by learning from past performance and adapting to current manufacturing conditions.
3Manufacturing precision
If the system provides detailed suggestions and recommendations for order combinations, then manufacturing precision improves, but the ease of operation decreases due to increased complexity
Solution Approach 1:
The system provides different levels of detail and automation based on the specific context and user needs. For routine operations, the system offers detailed suggestions and recommendations. For experienced users or time-critical situations, the system allows for simpler, more direct control. This local quality approach ensures that the interface complexity matches the actual operational needs.
4Quantity of substance
If the system aggregates information from multiple discrete systems, then the quantity and quality of order information improves, but the device complexity increases
Solution Approach 1:
The controller is designed with universal interfaces and standardized data processing capabilities that can handle information from multiple discrete systems through a common architecture. This multi-functionality allows the system to aggregate information from various sources without requiring separate processing paths for each system, thereby managing complexity while maintaining information completeness.
Data Source
AI summary
Systems for providing efficient manufacturing of paper, sheet, and/or box products of varying size and structure, often with pre-applied print (“pre-print”), are provided herein. One or more controllers can be used to aggregate upcoming orders and information needed to complete the manufacturing process for the order. A controller enables a user to prepare control plans (e.g., reel maps, reel plans, etc.) for processing rolls of web product through the manufacturing process. Criteria filtering and/or various features enable generation of efficient and effective control plans for rolls of web product, including, in some cases, multiple orders. The control plan may include a set of instructions for operating one or more systems within the manufacturing process to form the desired finished paper-based product. In such a regard, efficient manufacturing of various paper-based products, including corrugated boxes, folded carton, labels, flexible paper, industrial bags, plates, cups, décor, and many others, can be achieved.