Expendable Component Support Control for Variable Replacement Lead Time
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Solution Overview
Problem
Existing systems fail to adapt to changes in the necessary time for expendable component replacement due to stock shortages or other factors, potentially leading to apparatus operation disruptions.
Innovation Solution
A support device that includes a computer to monitor consumption levels of expendable components, specify the necessary replacement time, and restrict or adjust operations based on actual lead times and consumption thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the replacement order is placed based on a fixed consumption threshold, then the ordering process is simple and automated, but the apparatus operation may be disrupted when replacement lead time increases due to stock shortages
Solution Approach 1:
The patent applies dynamics by making the consumption threshold variable rather than fixed. The threshold is dynamically adjusted based on the actual replacement lead time. When lead time increases due to stock shortages, the threshold is lowered to trigger earlier ordering. This resolves the contradiction by maintaining automated ordering simplicity while adapting to changing conditions to ensure operational reliability.
Solution Approach 2:
The patent implements feedback by continuously monitoring the actual replacement lead time and using this information to adjust the consumption threshold. The system receives feedback about stock status and lead time changes, then modifies the ordering trigger point accordingly. This feedback loop ensures that the automated system adapts to real-world variations in supply chain conditions, preventing operational disruptions.
2Reliability
If the consumption threshold is lowered to account for longer replacement lead times, then the apparatus operation continuity is maintained, but the ordering frequency increases and may cause waste
Solution Approach 1:
The patent uses dynamics to adjust the threshold only when necessary - specifically when actual lead time exceeds a reference lead time. The threshold isn't permanently lowered but dynamically adjusted based on current lead time conditions. This resolves the contradiction by maintaining operation continuity during critical periods while avoiding excessive ordering frequency during normal conditions, thus preventing waste.
Solution Approach 2:
The patent changes the parameter of consumption threshold based on lead time conditions. When lead time increases, the threshold parameter is adjusted to a lower value to trigger earlier ordering. When lead time returns to normal, the threshold returns to its original value. This parameter change approach ensures operation continuity during disruptions while minimizing unnecessary ordering frequency and potential waste during normal operations.
Data Source
AI summary
The technology disclosed in the present specification is embodied as a support device for supporting maintenance on an apparatus including an expendable component. The support device includes at least one computer. The at least one computer executes: a process of acquiring an index indicative of a consumption level of the expendable component; a process of, at a time point when the index indicative the consumption level reaches a predetermined threshold, specifying a necessary period of time required for replacement of the expendable component at the time point; and a process of restricting an operation of the apparatus when a remaining period of time of the expendable component, the remaining period of time being associated with the threshold, is shorter than the necessary period of time required for the replacement.