Production Buffer Management Using Predictive Process Segmentation
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Solution Overview
Problem
Existing management systems struggle to effectively manage buffers in production and logistics systems with minimal assets, particularly in handling bottlenecks caused by irregularities such as peak seasons, machine failures, or operator variations, which are not adequately addressed by existing techniques.
Innovation Solution
A management device that specifies storage places, divides processes into smaller units, sets pre- and post-processes, calculates input and output requirements based on shipping plans, and adjusts resources to optimize buffer management, using mathematical models and predictive control to minimize surplus and ensure smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If buffers are reduced to implement asset light management, then asset holding is minimized, but the system becomes vulnerable to bottlenecks and irregularities in process operations
Solution Approach 1:
The system performs preliminary actions by predicting future bottlenecks and irregularities before they occur. The prediction unit forecasts potential process disruptions, and the determination unit pre-calculates optimal buffer allocations, enabling the system to prepare in advance rather than reactively managing buffers after problems arise.
Solution Approach 2:
The system implements dynamic buffer management where buffer inventory levels are not fixed but continuously adjusted based on real-time process conditions and predictions. The determination unit dynamically calculates buffer amounts by considering varying process capabilities, shipping plans, and predicted irregularities, allowing the buffer size to adapt flexibly to changing system states.
2Reliability
If buffers are increased to ensure process continuity, then reliability is improved, but asset holding increases contrary to asset light management goals
Solution Approach 1:
The system changes the parameter of buffer inventory from a static, uniform value to a dynamic, variable quantity. The determination unit calculates specific buffer amounts for different time periods and process segments based on predicted needs, transforming the buffer from a constant safety stock to an optimized, time-varying inventory level that matches actual process requirements.
Solution Approach 2:
The system applies different buffer levels to different process segments and time periods rather than using a uniform buffer throughout. The determination unit identifies specific locations and times where buffers are most needed based on predicted bottlenecks, concentrating buffer inventory in critical areas while minimizing it in non-critical areas, thus achieving local optimization.
3Measurement precision
If the system divides processes into small processes, then buffer management precision is improved, but system complexity increases
Solution Approach 1:
The system segments the overall process into multiple small processes, with each having its own buffer management. This segmentation allows precise control and prediction for each segment, enabling the determination unit to calculate buffer needs for individual processes rather than managing a single large buffer, thereby improving management precision through division.
Solution Approach 2:
The determination unit serves multiple functions: it predicts bottlenecks, forecasts irregularities, calculates buffer amounts, and coordinates between different small processes. This multi-functional component consolidates the complexity into a single intelligent unit that manages all segmented processes, reducing overall system complexity despite the segmentation.
Data Source
AI summary
A management device includes a storage place necessary for storage between processes specified among a series of processes leading to shipping of products. The series of processes is divided into small processes based on the specified storage place. A small process behind the storage place in time series is set as a post-process, and a small process ahead of the storage place in time series is set as a pre-process. An input and output required for the post process are calculated based on dealing ability of the post-process, dealing ability of the pre-process and a shipping plan having a target value of a shipping amount and a shipping time. An input and output required for the pre-process are calculated. The storage amount in the storage place disposed between the post-process and the pre-process is calculated based on the calculated input for the post-process and the calculated output for the pre-process.