Dynamic Production Planning for Manufacturing Delay Recovery
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Solution Overview
Problem
In large-scale factories producing various products, manual provision of work deployment, progress situation, and necessary knowledge and experience for work items leads to increased man-hours and inefficiencies in responding to manufacturing delays.
Innovation Solution
A dynamic production planning system that includes a dynamic production planning device with a process actual result storage unit, a process plan actual result storage unit, and a recovery scenario generating unit to calculate delay risk indices, enabling quick recovery plans by analyzing production time and facility usage for each item and process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual provision of work deployment and progress information is used, then information accuracy is maintained, but man-hours and operational complexity increase significantly
Solution Approach 1:
The system enables automatic self-service by having production facilities and work items autonomously report their status, progress, and delays to the management device, eliminating the need for manual information provision while maintaining data accuracy
Solution Approach 2:
The patent replaces the mechanical manual information gathering system with an automated electronic information processing system where the management device automatically collects, stores, and analyzes production data from connected facilities and work items
2Productivity
If automated information collection is implemented, then operational efficiency improves, but system complexity increases
Solution Approach 1:
The management device serves multiple functions including automatic information collection, delay detection, recovery plan generation, and production optimization, consolidating what would otherwise require separate systems into a single multi-functional platform
Solution Approach 2:
The management device acts as an intermediary between production facilities and decision-makers, automatically collecting data from facilities and generating actionable recovery plans, thereby simplifying the overall system architecture while maintaining high productivity
3Manufacturing precision
If detailed manual tracking is performed, then production control precision is improved, but response time to delays increases
Solution Approach 1:
The system implements continuous feedback by automatically monitoring work item progress and comparing actual progress against planned schedules, immediately detecting delays and triggering automatic recovery plan generation without manual intervention
Solution Approach 2:
The management device pre-calculates and stores multiple recovery plans in advance for various delay scenarios, enabling immediate deployment of appropriate recovery actions when delays are detected, thereby reducing response time while maintaining precision
Data Source
AI summary
An object of the invention is to quickly provide an effective recovery plan for a delay problem occurring at a manufacturing site. A dynamic production planning system includes a dynamic production planning device, and the dynamic production planning device includes a process actual result storage unit that includes a record of time spent on production for each item and process, a process plan actual result storage unit that includes a production facility of which usage is planned and assumed work time thereof for each item and process, and a recovery scenario generating unit configured to calculate, for each item and process, an index indicating a risk of a delay using the time spent on production and the production facility of which usage is planned and the assumed work time thereof for each item and process.