Automatic Process Modeling for Mixed Flow Shop and Job Shop
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Solution Overview
Problem
Existing process model generation methods struggle to efficiently combine flow shops and job shops, leading to complex data visualization and labor-intensive input errors, especially when dealing with varying production systems.
Innovation Solution
A system and method that automatically generate a process model by analyzing work performance data, identifying closed paths as job shops and other areas as flow shops, allowing for seamless integration of both systems, with manual correction capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flow shop system is used to visualize process order and simplify input data, then the process order can be visualized and input data is simplified, but as the amount of site data increases, the process order becomes more complicated and adding patterns becomes more difficult
Solution Approach 1:
The patent segments the production process into multiple process models, where each process model represents a specific process or operation. By dividing the overall complex process order into smaller, manageable process models, the system can handle large amounts of site data without becoming overwhelming. Each process model can be independently configured and managed, making it easier to add patterns and modifications without complicating the entire system.
2Adaptability or versatility
If a job shop system is used to allow random process order and flexible process selection, then the display screen is simplified and adding patterns is easy, but the process order cannot be visualized and labor and input errors increase
Solution Approach 1:
The patent implements feedback mechanisms where the system automatically generates process models based on analyzed site data, and this generated information is fed back to users for verification and correction. The system provides visual feedback through process flow visualizations that show the actual process order derived from site data, allowing users to see and verify the process sequences while maintaining the flexibility of job shop systems.
3Productivity
If manual analysis of site data is performed to improve work efficiency, then the work efficiency of individual tasks is improved, but cooperation among departments is difficult due to different task management systems
Solution Approach 1:
The patent creates a universal process model generation system that can handle site data from multiple different task management systems and departments. The system uses a standardized process model structure that can represent various types of tasks and processes across different departments, enabling information sharing and cooperation while maintaining the specific characteristics of each department's task management system.
4Manufacturing precision
If process models are generated manually to ensure accuracy, then the quality of process models is maintained, but the time and labor required for generation increases
Solution Approach 1:
The patent performs preliminary actions by automatically analyzing site data and pre-generating process models before manual review. The system prepares draft process models based on the analyzed data, which then can be reviewed and corrected by users. This preliminary automatic generation reduces the time and effort required for manual model creation while maintaining accuracy through subsequent verification steps.
Data Source
AI summary
A production system between processes is automatically determined using work performance data acquired at a production site, and a process model in which a flow shop and a job shop are mixed is automatically generated. A process model automatic generation system 210 reads work performance data from work performance data 120 and extracts a process flow for each product (130). Next, a synthesis flow obtained by combining a plurality of process flows is created, and a production system between processes corresponding to a closed path is changed to a job shop to automatically determine a production system (140). Finally, a process model in which a flow shop and a job shop are mixed is generated (150) and displayed on a display screen 160.