Production Line Task Allocation for Mixed Worker-Machine Assembly
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Solution Overview
Problem
Production line designers face difficulties in creating optimal line proposals that can handle mixed flow production and fluctuations in production volume, especially with a decreasing number of production workers, and existing technologies do not provide a method to efficiently allocate tasks between workers and automatic machines.
Innovation Solution
A line configuration planning device that determines task sequences and allocates tasks between workers and automatic machines based on operation information, equipment configuration, and production plans to generate a suitable production line configuration, ensuring an estimated cycle time is less than or equal to the required cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If production line designers rely on experience to create line proposals, then task allocation can be optimized based on expert knowledge, but it becomes increasingly difficult to create optimal proposals as the number of production workers decreases and production complexity increases
Solution Approach 1:
The patent replaces the mechanical system of human expert judgment and experience-based design with an automated computational system. The line configuration planning device uses processors to automatically generate task sequences, calculate cycle times, and allocate workers and machines based on input parameters, eliminating the need for designers to manually analyze complex production scenarios.
Solution Approach 2:
The system enables self-service by allowing the production line configuration to be automatically generated from basic input data (product information, production volume, equipment list). The device independently performs task decomposition, sequence determination, and resource allocation without requiring continuous human intervention or expert judgment throughout the design process.
2Adaptability or versatility
If manual task allocation methods are used, then flexibility in adjusting to mixed flow production and volume fluctuations can be achieved through expert judgment, but the time required to derive suitable configurations increases significantly
Solution Approach 1:
The system performs preliminary action by pre-calculating task sequences and cycle times based on input parameters. The device determines the optimal task sequence and resource allocation in advance, allowing rapid adjustment to different production scenarios by simply changing input data rather than manually reanalyzing each scenario.
Solution Approach 2:
The system exhibits dynamics by automatically adapting the production line configuration to changing conditions. When production volume, product mix, or equipment availability changes, the device recalculates task sequences and resource allocations to optimize performance for the new conditions, providing real-time adaptability.
3Productivity
If existing allocation methods are used that only distribute tasks to automatic machines, then machine utilization can be optimized, but efficient allocation of tasks between workers and automatic machines cannot be achieved
Solution Approach 1:
The patent applies universality by creating a unified task allocation framework that handles both manual and automatic tasks within a single system. The line configuration planning device determines optimal task sequences and allocates tasks to either workers or automatic machines based on task characteristics, production requirements, and resource availability, rather than treating manual and automatic allocation as separate processes.
Data Source
AI summary
A line configuration planning device determine a task sequence during production of the to-be-produced product and the task time by the worker or the automatic machine for each task on the basis of the task information and the task time information. The line configuration planning device determine a required cycle time for producing the to-be-produced product on the basis of the production plan information. The line configuration planning device generate, on the basis of the determined task sequence, task time, and required cycle time, an allocation proposal for the worker and the automatic machine such that an estimated cycle time for producing the to-be-produced product is less than or equal to the required cycle time. The line configuration planning device determine a production line configuration for the to-be-produced product on the basis of the allocation proposal and the equipment configuration information.