Production Machine Visualization for Process Time Bottlenecks
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Solution Overview
Problem
Existing production machines lack an objective basis for time optimization of complex production programs, making it difficult for operators to identify and optimize speed-determining process sequences, especially when steps run concurrently, in parallel, or overlap, and involve various stations and tools.
Innovation Solution
A control program for production machines that provides a visualization unit to highlight speed-determining stations and components, offering interactive input for time value adjustments, allowing for an objective optimization of process parameters and visualization of time phases, enabling operators to quickly improve production time efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a production machine operates with multiple stations and parallel processes, then productivity increases, but it becomes extremely difficult to identify speed-determining process sequences
Solution Approach 1:
The system uses color-coded visualization to highlight speed-determining stations and machine components in the flow chart. Critical elements are displayed with distinct colors or visual emphasis, enabling operators to quickly identify which stations or components are limiting overall production speed without having to manually analyze complex parallel processes
Solution Approach 2:
The control program acts as an intermediary that automatically analyzes the complex production program and calculates speed-determining elements. Instead of requiring the operator to manually trace through multiple parallel and overlapping processes, the control program performs the complex analysis and presents the results in an easily interpretable visual format
2Loss of time
If operators use trial-and-error methods to optimize process time, then they may find improvements, but the process requires costly machine initialization and repeated testing
Solution Approach 1:
The system performs preliminary analysis of the production program to identify speed-determining stations and components before actual production optimization begins. By pre-calculating which elements limit production speed and displaying them prominently in the flow chart, operators can make targeted adjustments without needing to run multiple trial productions, thereby avoiding costly machine initialization and energy consumption
3Productivity
If process steps run in parallel or overlap across multiple stations, then production efficiency improves, but the complexity of visualizing and optimizing the process increases
Solution Approach 1:
The system segments the complex production process into individual stations and machine components that can be separately visualized in the flow chart. Each station and component is represented as a distinct element with its own time bar, making it easier to understand parallel and overlapping processes. The segmentation allows operators to focus on specific stations or components without being overwhelmed by the entire complex process
Data Source
AI summary
The invention relates to a production machine with a control program for visualizing stations and/or machine components, highlighting the speed-determining station and/or the speed-determining machine component in order to optimize the process time. The invention also relates to a method of optimizing the process time for a production machine with such a control program and to a data carrier with such a control program.