Production Line Workload Balancing Using Variant Probability Maps
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Solution Overview
Problem
Current interactive techniques for workload balancing in multi-variant serial production lines are complex and unsatisfactory, making it difficult for product line managers to balance operations across resources while considering variant probabilities, cycle times, and takt-times, leading to potential production bottlenecks and inefficiencies.
Innovation Solution
A method and system that use graphic objects to represent variant probabilities and workload times on a 2D screen, allowing for interactive balancing actions such as moving operations between resources, adding or removing resources, and modifying the variant mix, facilitated by a processor-based system that takes into account measurable parameters like object size and position relative to the takt-time line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If current interactive techniques are used for workload balancing, then product line managers can visualize production parameters, but the techniques are complex and unsatisfactory, leading to difficulty in balancing operations
Solution Approach 1:
The patent creates a simplified graphical copy of the production line where resources are represented as visual elements and workload balancing is achieved through intuitive graphical interactions rather than complex computational techniques. The graphical interface copies essential production parameters in a simplified visual format that managers can easily manipulate.
Solution Approach 2:
The patent replaces complex computational and interactive techniques with a graphical user interface that uses visual drag-and-drop mechanisms. This substitution transforms complicated balancing algorithms into simple graphical operations, making the system easier to operate while maintaining balancing effectiveness.
2Manufacturing precision
If detailed production parameters are considered for accurate balancing, then balancing precision improves, but the complexity of managing multiple parameters increases
Solution Approach 1:
The patent transforms multiple one-dimensional production parameters into a two-dimensional graphical representation. Resources, workloads, and timing parameters are displayed together in a visual space where managers can see relationships between parameters without managing each separately, maintaining precision while reducing management complexity.
Solution Approach 2:
The patent merges multiple production parameters (workload times, takt-times, variant probabilities) into unified graphical elements. Instead of managing separate parameters, the system combines them into visual representations where balancing actions automatically consider all relevant parameters simultaneously, improving precision without increasing management burden.
3Loss of information
If visual information on production parameters is displayed, then managers can make interactive decisions, but current 2D graphic screens are insufficient for the complexity of the task
Solution Approach 1:
The patent enhances traditional 2D graphic screens by adding visual dimensions such as color coding, size variations, and spatial relationships that encode additional production information. This allows comprehensive display of variant probabilities, workload times, and resource capacities without increasing interface complexity, preventing information loss while maintaining usability.
Data Source
AI summary
Methods and a system include getting, for each variant, input on a probability of occurring and inputs on a variant assigned workload time for a given resource. For each resource of the line, each variant is represented with a graphic object having a first measurable parameter representing the variant probability and a second measurable parameter representing the variant assigned workload time. At least one resource requiring workload balancing on a specific variant is determined by taking into account a combination of the first measurable parameter and the second measurable parameter of the specific variant.