Modular Production Line Layout Planning for Plant Space Constraints
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Solution Overview
Problem
Conventional modular plant construction systems lack consideration for physical arrangement and interaction of modules, leading to difficulties in determining suitability for actual plant spaces and insufficient flexibility for rearrangement and expansion, which are critical for modern manufacturing industries responding to market fluctuations.
Innovation Solution
A construction system that acquires construction information including MTP and physical details of modules, generating a configuration and arrangement plan that considers physical characteristics and carry-in destinations, enabling optimal process flows and production schedules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional MTP technology is used to construct production lines by combining independent modules, then flexibility and efficiency of the manufacturing process are improved, but physical arrangement and suitability for actual plant spaces are not considered
Solution Approach 1:
The system segments the plant construction process into two distinct phases: logical-level module selection using MTP technology, and physical-level arrangement planning. This segmentation allows each phase to be optimized independently - logical flexibility through module selection and physical suitability through arrangement planning with constraints
Solution Approach 2:
The system performs preliminary action by generating multiple candidate arrangement plans before final implementation. The arrangement plan generation unit creates several possible configurations, and the suitability determination unit evaluates each against physical constraints, allowing optimization before actual plant construction
2Productivity
If modules are selected and combined during the design phase based on logical cooperation, then process flow optimization is achieved, but physical arrangement constraints are not considered
Solution Approach 1:
The system transitions from two-dimensional logical process flow design to three-dimensional physical arrangement planning. The arrangement plan generation unit considers spatial dimensions (length, width, height) and physical constraints (power supply, water supply, discharge) that were absent in conventional logical-level design
3Loss of time
If a modular plant is designed without considering physical characteristics, then design speed is improved, but adaptability to actual plant conditions deteriorates
Solution Approach 1:
The system creates a virtual copy of the physical plant environment including constraints (power supply locations, water supply, discharge points, spatial dimensions) and uses this copied environment to evaluate and optimize arrangement plans, ensuring adaptability without requiring multiple physical design iterations
Data Source
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AI summary
A device (A) for constructing a production line includes: an acquisition unit (14) configured to acquire construction information (15) including definition information (32) defining a function, performance, and interface requirements of a module (M) in a modular plant, and physical information (33) including physical characteristics of the module (M) and information on a carry-in destination of the module (M); and a generation unit (14) configured to generate, based on the acquired construction information (15), a configuration and an arrangement plan of the module (M).