Mixed-Flow Production Sequencing to Prevent Local Work Line Congestion
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Solution Overview
Problem
In multi-type mixed-flow production, the same type of product is often consecutively fed into a work line, leading to repeated work and decreased efficiency, and while target tracking methods attempt to equalize the feeding order, they can still result in local congestion due to biased supply frequencies.
Innovation Solution
A planning program that dynamically adjusts the selection of product types based on their appearance probability, calculated by considering the completion ratio of each type, to prevent continuous selection of the same product and reduce congestion by introducing interval and continuity constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If target tracking method is used to equalize feeding order for each type, then process order equalization is improved, but local congestion still occurs
Solution Approach 1:
The patent applies dynamics by making the selection frequency of each product type adjustable and changeable over time. The system dynamically modifies the frequency with which each product type is selected based on real-time work line status, allowing the feeding order to adapt to changing conditions and prevent local congestion while maintaining overall equalization.
Solution Approach 2:
The patent changes the parameter of selection frequency for each product type. By adjusting these frequencies based on completion ratios and current work line state, the system can prevent local congestion while maintaining equalized process ordering. This involves modifying the probability parameters used in selecting which product type to feed next.
2Productivity
If same type is consecutive in process order, then work efficiency decreases due to repeated work, but changing selection frequency increases system complexity
Solution Approach 1:
The patent implements feedback by continuously monitoring the completion ratio of each product type and using this information to adjust the selection frequency for future feedings. This closed-loop control ensures that product types which have been completed are selected more frequently, preventing repetition and maintaining high work efficiency without requiring complex manual intervention.
Solution Approach 2:
The system performs self-service by automatically adjusting its own selection frequencies based on its internal state (completion ratios). The planning program autonomously modifies the feeding sequence without external intervention, using its own performance data to optimize future operations and prevent repeated processing of the same product type.
Data Source
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Figure 3A~3C
AI summary
A planning program that causes at least one computer to execute a process, the process includes specifying a process order of a plurality of types of objects in a work line for processing the plurality of types of objects; specifying a ratio of a number of objects of one of the plurality of types to the total number of the plurality of types for each of the plurality of types; acquiring an appearance probability obtained by subtracting the number of objects of a type of which the process order is determined, from a product of a process number and the ratio; selecting the type to be processed next by using the appearance probability; and changing a frequency of the selecting according to a completion ratio of a number of types which the selecting is completed to the total number of the plurality of types.