Factory Planning Layout for Productivity-Driven Resource Scheduling
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Solution Overview
Problem
Existing methods for designing manufacturing lines require an enormous number of combinations to maximize productivity indices, leading to excessive man-hours in generating a factory plan.
Innovation Solution
A factory plan device that includes a calculation unit to specify processes and production resources based on past performance data, design data, and layout data to optimize process order, resource allocation, and working times to maximize a productivity index.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing methods generate process flows and equipment layouts sequentially based on product information, then the manufacturing line design can be completed, but the number of man-hours required becomes enormous due to the need to evaluate enormous combinations of process orders and resource allocations
Solution Approach 1:
The system performs preliminary actions by pre-calculating and storing process information, resource information, and their relationships in databases before actual factory planning. Process flows are generated in advance based on product information, and equipment layouts are pre-configured with associated resources. This preliminary preparation eliminates the need to evaluate enormous combinations during the actual planning phase, significantly reducing the time required to generate factory plans while maintaining optimal productivity.
2Productivity
If the process order and resource allocation are optimized to maximize productivity indices such as equipment operation efficiency and production throughput, then manufacturing efficiency improves, but the complexity of evaluating all possible combinations increases enormously
Solution Approach 1:
The system segments the factory planning process into independent modular components: product information management, process flow generation, resource information management, equipment layout design, and automatic plan generation. Each module handles specific aspects of optimization independently, storing pre-processed data in databases. This segmentation allows the system to evaluate productivity indices for each module separately without requiring complex evaluation of all possible combinations simultaneously, thereby reducing system complexity while maintaining optimization capability.
3Manufacturing precision
If comprehensive production resource information including equipment specifications and location constraints is collected and analyzed, then the accuracy of factory planning improves, but the data processing time and computational requirements increase
Solution Approach 1:
The system performs preliminary data processing by collecting, validating, and storing comprehensive production resource information in structured databases before actual factory planning. Equipment specifications, location constraints, and resource capabilities are pre-processed and organized in advance. This preliminary action ensures high factory plan accuracy by having complete resource information readily available, while eliminating the need for time-consuming data processing during the actual planning phase.
Data Source
AI summary
It is possible to more efficiently make a factory plan configured to maximize a productivity index.Provided is a factory plan device including a calculation unit configured to specify a process and a production resource candidate based on a shape of a component of a target product by inputting past production performance data of a product, production volume data, design data of the product, specification data of a production resource, and layout data of a factory, and to calculate a process plan configured to determine order of the process and the production resource, a production plan configured to determine working date and time of the production resource, and a layout of the production resource so as to maximize a predetermined productivity index in the factory.