Production Line Lead Time Analysis for Workpiece-Level Anomaly Tracing
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Solution Overview
Problem
Existing production line analysis techniques fail to identify the cause of anomalies in individual workpieces, as they focus on average production volume and lead time, unable to pinpoint specific issues.
Innovation Solution
A production line analysis system and method that displays a lead time distribution of workpieces, allows operator input to select a workpiece, and provides detailed information on equipment at the time of selection, including various viewpoints to identify anomalies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simulation results are displayed showing average production volume and average lead time, then overall production line performance can be evaluated, but the cause of anomaly in individual workpiece cannot be identified
Solution Approach 1:
The patent segments the aggregate simulation data into individual workpiece-level data. Instead of displaying only average production volume and average lead time, the system divides the data to show lead time distribution across multiple workpieces, enabling operators to select and analyze specific workpieces that exhibit abnormal behavior. This segmentation resolves the contradiction by preserving individual workpiece information while maintaining overall performance evaluation capabilities.
Solution Approach 2:
The patent adds a new dimension to the data display by introducing workpiece selection capability. The system transitions from a single aggregate view (average metrics) to a multi-dimensional view that includes individual workpiece lead times. This dimensional expansion allows operators to drill down from overall performance to specific workpiece anomalies, thereby identifying causes that were previously hidden in aggregated data.
2Measurement precision
If detailed information for each workpiece is displayed, then cause of anomaly can be identified, but information processing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing lead time distribution data for multiple workpieces during the simulation phase. Instead of processing raw simulation data in real-time when anomalies are detected, the system prepares workpiece-level lead time information in advance. This preliminary preparation reduces the processing complexity during anomaly investigation, as operators can directly query pre-processed data rather than performing complex real-time analysis.
Solution Approach 2:
The patent introduces an intermediary data structure that stores lead time distribution information for multiple workpieces. This intermediary layer acts as a buffer between the simulation engine and the display interface, organizing detailed workpiece information in a structured format that is efficient for both storage and retrieval. The intermediary data structure reduces processing complexity by providing a standardized interface for accessing individual workpiece details without requiring complex data transformation during query operations.
Data Source
AI summary
A production line analysis system includes one or more processors, a display device, and a user interface. The one or more processors are configured to: display, on the display device, a first window showing a lead time distribution of a plurality of workpieces that have passed through first equipment included in one or more pieces of equipment, based on a result of a simulation of a production line including the one or more pieces of equipment; receive, through the user interface, a first operator input to select one of the plurality of workpieces displayed in the first window; and, in response to the first operator input, display, on the display device, detailed information regarding the first equipment at a time when a selected workpiece, which is a workpiece selected by the first operator input, passes through the first equipment.