Dynamic Value Stream Map Simulation for Process Bottleneck Analysis
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Solution Overview
Problem
Current value stream maps and process simulations lack a dynamic aspect, failing to consider changes in process constraints and product mix, which limits their effectiveness in identifying productivity improvements and optimizing process flows.
Innovation Solution
A computer-readable medium with instructions that implement a method to dynamically simulate and analyze process flows using a state engine to manage operations rules, identify and modify productivity parameters, and create dynamic value stream maps, allowing for real-time updates and scenario analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional value stream maps are used to analyze process flows, then basic productivity identification is achieved, but dynamic aspects and product mix changes are not considered
Solution Approach 1:
The patent applies dynamics by transforming static value stream maps into dynamic simulations that can adapt to changing process constraints and product mixes. The system uses executable models that automatically update when process parameters change, enabling real-time analysis of productivity improvements without requiring manual remapping.
Solution Approach 2:
The system changes parameters by allowing dynamic modification of process constraints, product mix ratios, and operational parameters within the simulation model. These parameter changes automatically trigger re-simulation to identify new productivity improvement opportunities, resolving the contradiction between adaptability and productivity analysis capability.
2Productivity
If Six Sigma and lean tools are integrated to improve productivity, then productivity improvements are achieved, but further process map studies require off-line simulation model building and validation
Solution Approach 1:
The patent applies preliminary action by pre-building a comprehensive executable process model that incorporates both Six Sigma and lean analysis capabilities. This preliminary model structure allows for rapid scenario testing and productivity analysis without requiring time-consuming off-line model building and validation for each new analysis requirement.
Solution Approach 2:
The system achieves universality by creating a multi-functional simulation platform that integrates Six Sigma statistical analysis, lean value stream mapping, and productivity optimization capabilities into a single executable model. This universal model can address multiple analysis requirements simultaneously, eliminating the need for separate model building and validation processes.
3Manufacturing precision
If process maps are updated to reflect new tasks and constraints, then current process accuracy is improved, but dynamic simulation and scenario analysis capabilities are lacking
Solution Approach 1:
The patent transforms accurate but static process maps into dynamic simulation models that maintain precision while adding adaptability. The executable model preserves the accuracy of detailed process information while enabling dynamic scenario analysis, product mix variations, and constraint changes without sacrificing manufacturing precision.
Data Source
AI summary
A computer readable medium comprising instructions which when executed by a computer system causes the computer to implement a method for creating a dynamic value network map of a process flow is provided. For a plurality of processed objects, the method identifies corresponding value stream metrics and triggers a state engine to simulate the process flow. The state engine is configured to manage all operations rules related to the value network map. The method dynamically updates the value stream metrics during the simulation of the value network map.