Modular Production Self-Synchronization via Duration Optimization

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Solution Overview

Problem

Modular production systems, such as printing systems with multiple components, often operate sub-optimally due to lack of self-synchronization, requiring manual or spreadsheet-based analysis for optimal productivity, which is limited to linear configurations and does not address complex systems with multiple operational modules.

Innovation Solution

A method and system for self-synchronization of modular production systems that determines job requirements, component durations, and default self-synchronization times, optimizing these by adjusting component duration times to ensure all system capabilities are utilized maximally, enabling automatic synchronization of modules and maximizing productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual or spreadsheet-based analysis is used to determine system parameters, then self-synchronization can be achieved in simple linear configurations, but the method cannot address complex systems with multiple operational modules and alternative capabilities

Engineering Contradiction:

Improvecapability to handle complex system configurationsVSAvoidsystem configuration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces manual spreadsheet-based analysis with an automated computer-based planning and scheduling system. The system uses software to automatically determine optimal component duration times and synchronize multiple operational modules, eliminating the need for manual calculation and enabling handling of complex configurations that would be intractable using traditional methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-synchronization by automatically calculating and adjusting component duration times based on system configuration and job requirements. The planning and scheduling software autonomously optimizes the timing parameters without requiring manual intervention, allowing the system to adapt to different configurations and maximize productivity independently.

Inventive Principle:

Principle #25Self-service

2Productivity

If system parameters are manually tuned for optimal productivity, then simple linear configurations can be optimized, but expensive equipment may remain partly idle due to sub-optimal productivity in complex configurations

Engineering Contradiction:

Improvesystem productivityVSAvoidequipment idle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system automatically determines and optimizes component duration time parameters based on the specific system configuration and job requirements. By dynamically calculating the optimal timing parameters using computer-based planning and scheduling, the system ensures that all expensive equipment operates at full capacity without idle time, regardless of configuration complexity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The planning and scheduling system uses real-time information about system state, component capabilities, and job requirements to automatically adjust and optimize component duration times. This feedback mechanism ensures that the system continuously operates at optimal productivity levels, preventing equipment idle time by coordinating all modules based on current system conditions.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If modular production systems use multiple components with alternative capabilities, then system versatility increases, but achieving self-synchronization becomes complex and requires automated methods

Engineering Contradiction:

Improveoperational module versatilityVSAvoidsynchronization complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The planning and scheduling system serves as a universal control mechanism that can handle multiple operational modules with different capabilities and configurations. The software is designed to work with various system architectures (linear, tandem, redundant paths) and automatically determines optimal parameters for each configuration, providing a single unified solution for diverse modular production systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The computer-based planning and scheduling system acts as an intermediary between the multiple operational modules with alternative capabilities. It receives information about system configuration and job requirements, processes this information to determine optimal component duration times, and coordinates all modules to achieve self-synchronization, simplifying the operation of complex versatile systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS7512455B2Method for self-synchronization of modular production systems

Publication Date: 2009.03.31 GENESEE VALLEY INNOVATIONS LLC

AI summary

A system and method for self-synchronization of modular production systems having components with various alternative capabilities for processing and transporting work units along transport highways, for various component/transport highway configurations. The method includes determining jobs of interest, with each job requiring the production of at least one work unit. The configuration of the components, including at least one machine module, and the transport highway is determined. Each component duration time is determined and a default self-synchronization time is identified. The default self-synchronization time is optimized by adjusting not less than one component duration time.