Machine Schedule Adjustment for Maintenance and Removal Timing
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Solution Overview
Problem
Existing machine management methods often neglect condition-maintaining activities, leading to increased risks of machine failure and inadequate manufacturing quality, while also failing to accurately predict the actual course of machine operation, resulting in unplanned downtimes.
Innovation Solution
A machine management method that determines manufacturing and removal times based on process data, adjusts schedules to accommodate these times, and adds unplanned activities during downtimes to maintain machine condition and prevent losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If machines are operated with closely timed predetermined schedules to prevent downtime and increase productivity, then productivity increases, but condition-maintaining activities such as maintenance, cleaning, diagnostics and calibration are not adequately taken into account, increasing the risk of machine failure
Solution Approach 1:
The system performs preliminary determination of manufacturing times and removal times before schedule execution. By calculating these times in advance based on process data and comparing them, the system proactively identifies time conflicts and adjusts the schedule beforehand to ensure condition-maintaining activities are included, preventing machine failures before they occur.
Solution Approach 2:
The system uses feedback from process data to continuously improve schedule accuracy. By determining actual manufacturing and removal times based on measured process data and comparing them with planned times, the system learns from deviations and adjusts future schedules to better reflect real operational conditions, ensuring reliability while maintaining productivity.
2Extent of automation
If predetermined schedules are used to reduce manual operation time losses, then automation level increases, but the actual course of machine operation cannot be accurately predicted, leading to unplanned downtimes
Solution Approach 1:
The system incorporates feedback loops where actual manufacturing times and removal times are measured during operation, compared with predetermined values, and used to adjust future schedules. This continuous feedback mechanism enables the automated system to learn from actual performance and improve prediction accuracy over time, reducing unplanned downtimes while maintaining high automation levels.
Solution Approach 2:
The schedule determination process is made dynamic by allowing automatic adjustment of schedules based on actual process data. Rather than using static predetermined schedules, the system dynamically adapts timing parameters based on measured manufacturing and removal times, enabling accurate prediction of actual machine operation course while maintaining automation.
3Reliability
If the predetermined schedule is changed to accommodate unplanned activities, then machine condition maintenance is improved, but productivity decreases due to reorganization and elimination of condition-maintaining activities from the changed sequence
Solution Approach 1:
The system performs preliminary comparison of determined manufacturing times and removal times before finalizing the schedule. By identifying time conflicts in advance and proactively adjusting the schedule to include condition-maintaining activities, the system ensures these activities are integrated into the optimal time slots without requiring reactive reorganization that would eliminate them, thus maintaining both machine condition and productivity.
Data Source
AI summary
A machine management method for performing planned activities on a machine is provided. Workpieces are manufactured by the machine according to a predetermined schedule during a respective planned activity of the machine. Manufactured workpieces are sorted from a removal area of the machine into a deposition area during a further respective planned activity of the machine according to the predetermined schedule. The method includes determining a manufacturing time for the workpieces by a machine management system based on manufacturing process data of the machine, determining a removal time for sorting the workpieces by the machine management system based on removal process data, changing the predetermined schedule to obtain a changed schedule for the planned activities by the machine management system based on a comparison of the manufacturing time with the removal time, and transferring the changed schedule to a controller of the machine.