Priority Calculation Device for Manufacturing Lots
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Solution Overview
Problem
The Critical Ratio (CR) method for determining the priority of in-process items in manufacturing is unable to calculate priorities for items that have not been assigned a shipping timing, making it impossible to prioritize in-demand items effectively.
Innovation Solution
A priority calculation system that assigns priorities based on a product-type-basis demand ratio, using a device with a storage unit for demand and process information and a control unit to determine and assign priorities to lots based on their product-type-basis demand ratio, ensuring that lots with ratios closer to the demand ratio are prioritized.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the Critical Ratio (CR) method is used to prioritize in-process items, then the priority of in-demand items can be calculated, but it is impossible to calculate the priority of in-process items for which shipping timing has not been assigned
Solution Approach 1:
The patent extends the priority calculation system to handle both in-demand items (with shipping timing) and non-demand items (without shipping timing) through a unified demand ratio mechanism. The system calculates demand ratios for all in-process items regardless of whether shipping timing is assigned, making the priority calculation system universally applicable to all items in the manufacturing process.
Solution Approach 2:
The patent introduces a new parameter (demand ratio) to replace or supplement the traditional CR method parameters. By changing the calculation basis from time-based (CR) to demand-based (demand ratio), the system can handle both in-demand and non-demand items uniformly, resolving the limitation of the CR method.
2Productivity
If priority is assigned based on shortest shipping time (CR method), then urgent items are processed first, but items not in demand cannot be prioritized effectively
Solution Approach 1:
The patent implements a feedback mechanism where demand information is continuously monitored and used to adjust priority assignments. The system calculates demand ratios based on current demand information and uses this feedback to dynamically prioritize both in-demand and non-demand items, ensuring that demand information is not lost but rather utilized for comprehensive priority management.
Solution Approach 2:
The patent performs preliminary calculation of demand ratios for all items including those without assigned shipping timing. By pre-calculating demand ratios for non-demand items, the system prepares priority information in advance, enabling effective prioritization when these items need to be processed alongside in-demand items.
Data Source
AI summary
Priority can be calculated for works-in-process which are not in demand. A priority calculation device (110) comprises a priority calculation unit (124) which specifies a queue of lots in each production stage, a product category wherein the lot is to be used, and the number of components included in the lot, on the basis of information stored in a queue information storage area (115), and allocates priority for each lot so that when the specified lot is supplied to the production stage, a lot, by which a ratio of a component, in each product category, contained in a lot which is in a process subsequent to the process of the production stage is made closer to the ratio of demand in each product category specified by the information stored in a demand information storage area (113), is supplied into the production stage with higher priority.