Lean Production Resource Capacity Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for calculating resource capacities in lean production environments, such as print shops, often lead to overestimation due to uniform demand assumptions, resulting in excessive capacity requirements and inefficiencies, especially with demand fluctuations and multiple resources competing to satisfy balanced workflows.
Innovation Solution
The implementation of a multi-objective optimization using linear programming (LP) and a generalized geometrical algorithm to determine minimal resource capacities by estimating peak-demand production rates, allowing for hierarchical calculation of resource capacities based on prioritized resources, thereby optimizing resource utilization and reducing unnecessary capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional uniform demand assumptions are used to calculate resource capacities, then resource capacity calculations are simplified, but overestimation of peak demand rates occurs leading to excessive capacity requirements
Solution Approach 1:
The patent changes the calculation parameters from uniform demand assumptions to time-varying demand rates that account for job arrival patterns and due dates. By using job-specific time segments and calculating demand rates as q_j/(t_j2-t_j1) for each job, the system transforms the oversimplified uniform model into a more accurate time-dependent model that reduces overestimation while maintaining computational feasibility through structured parameter organization.
2Adaptability or versatility
If multiple resources are utilized to satisfy balanced lean workflow, then resource flexibility increases, but resources compete against one another requiring complex capacity balancing
Solution Approach 1:
The patent segments the multiple resources into a hierarchical structure with one critical resource and several substitute resources. This segmentation allows the system to manage complexity by treating resources differently - the critical resource determines the base production rate while substitute resources provide flexibility through defined substitution rules. The segmentation transforms the complex multi-resource balancing problem into a more manageable structure with clear roles for each resource type.
Solution Approach 2:
The patent introduces a workflow management system as an intermediary that coordinates resource allocation and handles the complexity of multi-resource balancing. This intermediary layer manages the competition between resources by implementing substitution rules and capacity balancing logic, shielding the core production process from the complexity of direct resource coordination while enabling flexible resource utilization.
3Ease of operation
If conventional takt-time calculation is used, then resource capacity estimation is straightforward, but substantial overestimation of necessary capacities results
Solution Approach 1:
The patent changes the demand rate calculation from the conventional uniform takt-time assumption to a time-varying model that uses job-specific parameters. Instead of assuming constant demand throughout the time segment, the system calculates demand rates as q_j/(t_j2-t_j1) for each job j, where t_j1 and t_j2 are the arrival and due dates. This parameter change enables more accurate measurement of peak demand rates while maintaining structured calculation procedures.
Data Source
AI summary
A plurality of printing jobs associated with a printing environment can be initially evaluated. Such a printing environment can be implemented as a print shop or another lean document production environment. A set of minimal resource capacities can then be calculated as a multi-objective optimization using a linear programming (LP) analysis. Alternatively, in a generalized geometrical algorithm, at least one peak-demand production rate associated with the most critical resource can first be estimated, in response to evaluating the plurality of printing jobs. Thereafter, minimal resource capacities of the plurality of resources of the printing environment can be hierarchically calculated based on estimating the previously determined peak-demand production rate of higher priority.