Process Control Device for Dynamic Sequence Order Adjustment
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Solution Overview
Problem
In production lines that manufacture a variety of products in small quantities, existing systems struggle to accurately control the sequence order of products and issue work instructions dynamically, especially when the sequence order changes at the field site, leading to inefficiencies and the need for manual confirmation by workers.
Innovation Solution
A process control system that includes a tracking control unit, conductor unit, work instruction unit, work instruction sequence order control unit, and storage unit, which receives event information about product location and sequence order, determines the appropriate process, issues work instructions, and stores sequence order information, allowing for real-time adjustments and reissuance of work instructions as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If work instruction sheets are issued based on pre-coordinated production schedules, then production planning is simplified, but the system cannot adapt to sequence order changes made at the field site
Solution Approach 1:
The system performs preliminary actions by pre-coordinating production schedules and preparing work instruction sheets in advance. However, it also implements real-time tracking and detection mechanisms that enable the system to detect sequence order changes at the field site and reissue work instructions accordingly, thus maintaining adaptability without excessive complexity
Solution Approach 2:
The patent implements feedback mechanisms where the system continuously monitors the actual sequence order of products at the field site and compares it with the planned sequence. When discrepancies are detected, the system automatically reissues work instruction sheets to match the actual sequence, enabling adaptability through real-time feedback without requiring complete system redesign
2Adaptability or versatility
If field workers manually confirm and adjust sequence orders, then flexibility is improved, but time consumption and operational efficiency deteriorate
Solution Approach 1:
The system implements self-service by automatically detecting sequence order changes through tracking mechanisms and autonomously reissuing work instruction sheets without requiring manual intervention from field workers. This maintains flexibility in adapting to sequence changes while eliminating the time consumption associated with manual confirmation and adjustment processes
Solution Approach 2:
The patent replaces the mechanical manual process of sequence order confirmation and adjustment with an automated electronic system. The tracking control unit automatically detects sequence changes and the work instruction unit automatically reissues instructions, substituting manual worker actions with automated mechanical/electronic processes that achieve the same flexibility without time loss
3Measurement precision
If the system tracks and controls sequence order information, then work instruction accuracy is improved, but information management complexity increases
Solution Approach 1:
The tracking control unit performs multiple functions: it tracks product sequence order, detects changes in sequence, and provides this information to the work instruction unit for reissuing instructions. By consolidating these related functions into a single multi-functional unit, the system achieves high sequence order accuracy without proportionally increasing information management complexity
Solution Approach 2:
The patent merges the tracking of sequence order information with the work instruction issuance process. The tracking control unit and work instruction unit operate as an integrated system where sequence information flow and instruction issuance are combined, reducing information management complexity while maintaining high accuracy in sequence order control
Data Source
AI summary
A process control device includes a tracking controller receiving event information indicating that a product pass a predetermined location is received; a conductor unit for determining a corresponding process based on the event information; and a work instruction unit for issuing a work instruction for the product in the production line in response to the request from the conductor unit. The device further includes a work instruction past record control unit for controlling past record of the work instructions in response to an issue of the work instruction; a work instruction sequence order control unit for controlling a sequence order of the work instructions; and a work instruction sequence order storage for storing information of the sequence order of the work instructions to control the information of the sequence order of the work instructions in addition to the current location information of the product.