Production Cycle Time Charts for Unstable Efficiency Analysis
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Solution Overview
Problem
Current production efficiency improvement systems rely on simple recognition of cycle time, which is insufficient for stabilizing production efficiency due to unstable variations, necessitating a deeper analysis of cycle time variations to identify causes for efficiency decreases.
Innovation Solution
A production efficiency improvement support system that calculates and visually displays cycle time variations using charts, allowing for accurate recognition of unstable cycles, with features like symbol density for visual recognition, statistical processing for actual cycle time representation, and alignment of operational availability and production volume on the same chart for comprehensive analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If simple recognition of cycle time is used, then the system is easy to operate, but the measurement precision is insufficient to identify causes of efficiency decreases
Solution Approach 1:
The patent transforms the cycle time data from a simple scalar value into a two-dimensional visual representation using charts with symbols positioned according to timing and cycle time values. This dimensional transformation enables precise recognition of cycle time variations and their patterns without increasing system complexity, as the visualization reveals causes of efficiency decreases that were previously hidden in raw numerical data.
2Measurement precision
If detailed analysis of cycle time variations is performed, then the measurement precision improves, but the loss of time increases due to complex analysis requirements
Solution Approach 1:
The patent replaces manual analysis of cycle time variations with an automated visual display system that graphically represents timing patterns. The chart automatically plots symbols at positions corresponding to timing and cycle time values, enabling operators to instantly recognize variations and their causes without performing complex manual analyses, thereby reducing analysis time while maintaining high measurement precision.
3Loss of information
If cycle time is displayed as a simple value, then the ease of operation is high, but the information completeness is insufficient for comprehensive analysis
Solution Approach 1:
The patent displays cycle time information in a two-dimensional chart where symbols are positioned according to both timing and cycle time values. This visual representation preserves all variation information while maintaining operational simplicity, as the chart intuitively shows timing patterns and relationships without requiring complex data tables or multiple separate displays.
Solution Approach 2:
The patent uses different colors for symbols representing different equipment or conditions, enabling comprehensive analysis of cycle time variations across multiple equipment types or operational states in a single visual display. This color-coding system provides complete information about sources of variations while keeping the display simple and easy to interpret at a glance.
Data Source
AI summary
A production efficiency improvement support system calculates a cycle time erc. based on results of detecting an operating status of production equipment, and displays a chart showing a time series variation of the cycle time etc. The cycle time is displayed such that a variation of the cycle time is visually recognizable. The chart displays information regarding a production volume that is the most important variable in production management on a first row and a second row from the top, and displays information regarding the operating status of the production equipment related to the production volume on bottom two rows (a fourth row and a fifth row). The chart also displays the operating status of the production equipment between these pieces of information. Displaying these indexes in the form of a chart facilitates visual recognition of how to improve the cycle time and effectively supports improvement of the production efficiency.