Kanban Ordering Feedback for Reliable Component Registration

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Solution Overview

Problem

The Kanban method for component ordering in automobile manufacturing plants requires manual verification to confirm if component ordering information is properly read and transmitted, limiting efficiency and reliability.

Innovation Solution

A component ordering system with a server and an ordering information reading device that automatically reads and transmits component ordering information from a Kanban card, determines if the information is registered in the server, and notifies the user if it is not, allowing for efficient and reliable ordering without additional special operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual verification is performed to confirm proper reading and transmission of component ordering information, then reliability is improved, but productivity deteriorates due to additional operational steps

Engineering Contradiction:

Improvereliability of component orderVSAvoidefficiency of ordering work

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs automatic verification where the reading device itself confirms whether component ordering information is properly registered in the server, eliminating the need for external manual verification. The device autonomously determines registration status and handles re-reading operations, making the system self-sufficient in verifying its own operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The server provides feedback to the reading device regarding whether component ordering information has been successfully registered. This feedback mechanism enables automatic verification without manual intervention, as the system receives confirmation signals from the server about the status of information registration.

Inventive Principle:

Principle #23Feedback

2Productivity

If component ordering information is automatically read and transmitted without verification, then productivity is improved, but reliability deteriorates due to potential reading errors

Engineering Contradiction:

Improveefficiency of ordering workVSAvoidaccuracy of component order

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs verification actions immediately after reading component ordering information, before the ordering process is completed. The reading device checks whether the information is properly registered in the server right after transmission, allowing for immediate detection and correction of any reading or transmission errors.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #23Feedback

3Reliability

If the reading device includes non-volatile memory to store ordering information, then reliability is improved, but device complexity and cost increase

Engineering Contradiction:

Improvedata retention capabilityVSAvoidcomplexity of reading device

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the data storage function from the reading device and places it in the server instead. The reading device only temporarily holds information in volatile memory during the reading and transmission process, while the server provides the persistent storage function, eliminating the need for expensive non-volatile memory in the reading device.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The server serves multiple functions including information reception, verification, storage, and feedback provision. By making the server multi-functional, the system eliminates the need for the reading device to have built-in non-volatile memory, as the server handles all persistent storage requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11216777B2Component ordering system

Publication Date: 2022.01.04 TOYOTA JIDOSHA KK

AI summary

A component ordering system that is efficient in component ordering work is provided, in which component ordering information read from a Kanban is transmitted to a server so that the server transmits the component ordering information to a component supplier. A bar-code reading device determines whether the component ordering information is registered in the server based on reply information transmitted from a server in response to information transmitted to the server after the Kanban is inserted into a Kanban insertion slot. When it is determined that the component ordering information is not registered in the server, the bar-code reading device notifies that the component ordering information is not registered while holding the Kanban without discharging it to the Kanban receiving part. Thus, it is possible to maintain reliability in component order as well as to improve efficiency in component ordering work.