Hierarchical Print Job Batching for Multi-Step Production Workflows
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Solution Overview
Problem
Existing batching methods for complex print jobs involving multiple production steps and components are inefficient due to the need for frequent switching between simplex and duplex printing, leading to productivity loss and complexity when unexpected issues arise.
Innovation Solution
A hierarchical batching method that organizes production into product-level and component-level subbatches, associating them based on a specified workflow, allowing for efficient scheduling and tracking of dependencies between production steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If complex print jobs with multiple components (book block, dust cover, book cover) are batched together on a single printer, then resource utilization is improved, but the number of plexity switches increases leading to productivity loss
Solution Approach 1:
The patent segments complex print jobs into separate component-level batches (book block batch, dust cover batch, book cover batch) that can be processed independently. Each component is treated as a separate entity with its own batch, allowing the printer to process homogeneous groups without frequent plexity switches, thereby reducing setup time while maintaining resource utilization
Solution Approach 2:
The patent introduces a hierarchical dimension to batching by creating multiple levels of batches: component-level batches for individual parts and product-level batches that coordinate them. This multi-dimensional batching structure allows simultaneous optimization of printer utilization at the product level while minimizing plexity switches at the component level
2Productivity
If similar components are batched separately (book block batch, dust cover batch, book cover batch), then plexity switches are minimized, but tracking and coordinating dependencies between production steps becomes complex
Solution Approach 1:
The patent implements a nested batch structure where component-level batches are nested within product-level batches. Each component batch (e.g., dust cover batch) is contained within a parent product batch (e.g., book product batch), allowing independent processing of components while maintaining hierarchical coordination through the nested structure
Solution Approach 2:
The patent establishes feedback mechanisms where completion status and dependency requirements are tracked between component batches and their parent product batch. The system monitors which components are complete and coordinates subsequent processing steps based on this feedback, enabling automatic coordination without manual intervention
3Ease of operation
If whole jobs are batched together as disclosed in US2009/033978 A1, then batch coordination is simplified, but flexibility to handle unexpected issues and optimize individual components is reduced
Solution Approach 1:
The patent creates a dynamic batch system where component-level batches can be independently adjusted, paused, or modified based on production needs while maintaining their connection to the parent product batch. This dynamic structure allows the system to adapt to unexpected issues (such as component failures or priority changes) without requiring changes to the entire batch, providing both ease of operation and production flexibility
Data Source
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AI summary
Method for batching the production of printed products that require more than one production step to be produced, the printed products comprising one or more components, the method comprising the steps of: creating a product level batch, specifying more than one product to be produced in the product level batch; determining a workflow specifying the production steps for producing the products in the product level batch; creating for a component of a product to be produced, and for a production step operating on the component as specified in the determined workflow, a subbatch for executing the production step on the component and associating the subbatch with the product level batch; and for subbatches created in the previous step, associating first and second subbatches wherein the first subbatch directly precedes the second subbatch in the determined workflow in that the output of the production step corresponding to the first subbatch serves as an input to the production step corresponding to the second subbatch as defined by the determined workflow.