Distributed Production Planning for Localized Re-Planning Decisions
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Solution Overview
Problem
Existing production planning systems lack a clear condition for determining the necessity of re-planning, leading to either unnecessary re-planning frequency or missed timing, disrupting manufacturing operations.
Innovation Solution
A distributed production planning and instruction apparatus that includes a storage unit for production data, a planning change necessity determination unit to assess re-planning needs based on abnormality stop periods, and a distributed planning generation unit to re-plan within localized target ranges, ensuring timely and necessary re-planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If re-planning is performed frequently to ensure production planning compliance, then production reliability is improved, but loss of time increases due to excessive re-planning operations
Solution Approach 1:
The system changes the parameter of re-planning trigger conditions by introducing specific determination criteria based on abnormality types and production element relationships. Instead of frequent or arbitrary re-planning, the system only initiates re-planning when specific parameters (abnormality occurrence, alternative element availability, compliance impact) are met, thereby reducing unnecessary re-planning operations while ensuring compliance when truly needed.
Solution Approach 2:
The system implements feedback mechanisms by continuously monitoring production element status, abnormality occurrences, and planning compliance. The planning change necessity determination unit receives feedback about abnormality events and systematically evaluates whether re-planning is necessary based on predefined criteria, creating a controlled response mechanism that avoids both excessive and insufficient re-planning.
2Reliability
If re-planning is performed across the entire production system to ensure comprehensive compliance, then production reliability is improved, but device complexity increases
Solution Approach 1:
The system segments the re-planning scope by introducing a re-planning scope determination unit that divides the production system into relevant and irrelevant portions based on abnormality location and element relationships. Instead of re-planning the entire production system, only the affected segments (specific production elements, processes, or facilities) are included in the re-planning target range, reducing complexity while maintaining compliance in critical areas.
Solution Approach 2:
The system applies local quality by making the re-planning scope variable and context-dependent. The re-planning scope is adjusted based on the specific abnormality type, the production element involved, and its relationships with other elements. This allows the system to concentrate re-planning resources on locally affected areas rather than applying uniform comprehensive re-planning across the entire system.
3Loss of time
If re-planning is delayed to reduce re-planning frequency, then loss of time is reduced, but production reliability deteriorates due to missed re-planning timing
Solution Approach 1:
The system performs preliminary action by pre-establishing determination criteria and alternative production element information before abnormalities occur. The facility-process relation information and alternative element data are prepared in advance, enabling the system to quickly evaluate re-planning necessity immediately upon abnormality detection without delay, thus maintaining both timely response and reduced overall re-planning frequency.
Data Source
AI summary
The apparatus includes: a storage unit configured to store a production instruction serving as an operation instruction for a production element including a production facility of a factory, a production resource, and an operator, production state information including an occurrence state of an abnormality of the production element, and facility-process relation information for identifying, for each process to be performed by the production element, another production element capable of alternatively performing the process; a planning change necessity determination unit configured to, when an abnormality in execution of the production instruction occurs in the production element, determine that planning change is unnecessary when the production instruction can be complied in consideration of a stop period of the production element that is caused by the abnormality; a distributed planning range calculation unit configured to include the another alternative production element in a re-planning target range; and a distributed planning generation unit.