Reusable Manufacturing Segments Data Model

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing manufacturing planning and execution systems face challenges in efficiently managing and maintaining manufacturing process data, particularly when product designs change frequently, as they require extensive manual updates and lack flexibility in reusing manufacturing segments across different processes and facilities.

Innovation Solution

A manufacturing production and process electronic data model is introduced, defining a manufacturing process in two levels with a top-level database object identifying the end output product and multiple linked production segment database objects, each specifying the necessary bill of material and process routing, allowing for the reuse of lower-level segments and generation of production orders.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manufacturing master data and routing definitions are defined in detail up front, then the manufacturing process can be controlled and tracked effectively, but the time and effort required for creating and maintaining the data increases significantly

Engineering Contradiction:

Improvecontrol and tracking of manufacturing operationsVSAvoidtime required for creating and maintaining master data

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The manufacturing process is divided into reusable segments that can be independently defined and then combined to create different production processes. Each segment represents a discrete manufacturing operation that can be reused across multiple products, significantly reducing the need to redefine the same operations repeatedly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Manufacturing segments are designed to be universal and can be applied to multiple different products and production processes. A single segment definition can serve multiple functions across different manufacturing scenarios, eliminating the need to create separate detailed definitions for each use case.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If manufacturing master data is defined specifically for each product, then the process can be optimized for that product, but the flexibility to adapt to product design changes is reduced

Engineering Contradiction:

Improveproduct-specific process optimizationVSAvoidflexibility to accommodate product design changes

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

By segmenting the manufacturing process into reusable components, the system allows product-specific optimization through selective combination of segments while maintaining adaptability. When product designs change, only the relevant segments need to be updated or recombined, rather than redesigning the entire manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system enables dynamic reconfiguration of manufacturing processes by allowing segments to be recombined in different ways as product designs evolve. The master data structure supports flexible assembly of segments to match changing product requirements without requiring complete redesign of the master data.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If separate execution activity definitions are created for each manufacturing operation, then the process can be controlled precisely, but the complexity of maintaining and updating the data increases

Engineering Contradiction:

Improveprecision of operation controlVSAvoidcomplexity of maintaining master data

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Execution activities are organized into segments that encapsulate specific manufacturing operations with their own precise control parameters. This segmentation allows precise control of each operation while simplifying maintenance, as changes to one segment do not propagate through the entire master data structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of maintaining unique detailed definitions for each operation across multiple products, the system uses templates and copies of segment definitions. This allows precise operation control through template-based segment definitions that can be instantiated and reused, reducing the overall complexity of maintaining master data.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS7555355B2Modeling production processes using reusable defined manufacturing segments

Publication Date: 2009.06.30 SAP SE

AI summary

A manufacturing production and process electronic data model and method of defining the model are provided, in which the model defines the manufacturing of a defined end output product. The electronic data model includes, firstly, a top-level database object that identifies the defined end output product. The electronic data model also includes multiple defined production segment database objects that are each linked to the top-level database object. Each linked production segment database object 1) identifies a defined segment output product, 2) includes a defined bill of material needed as inputs to produce the defined segment output product, and 3) includes a defined routing that describes how the defined segment output product is produced. One of the defined segment output products is the defined end output product.