Production Plan Verification for Multi-Line Capacity Constraints
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Solution Overview
Problem
Existing systems struggle to generate production plans with high accuracy due to variations in production lines and processes for different product types, leading to inefficiencies and equipment overload.
Innovation Solution
A generation system that includes an optimization calculation part, an input plan generator, and a verification part to create a production plan by optimizing workpiece processing across multiple production lines, considering constraints and equipment capacity, and verifying the plan through simulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated production plan generation is implemented, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The production plan generation is divided into multiple independent modules: optimization calculation part that generates processing plans, input plan generator that creates input plans, and verification part that checks appropriateness. Each module handles specific aspects of plan generation independently, improving overall system efficiency while maintaining accuracy through specialized processing at each stage
Solution Approach 2:
The verification part performs simulation-based checks on the generated processing and input plans, providing feedback on their appropriateness. This feedback mechanism allows the system to identify and correct inaccuracies in generated plans, thereby maintaining high manufacturing precision while benefiting from automated generation processes
2Productivity
If optimization calculation is performed, then productivity is improved, but device complexity increases
Solution Approach 1:
The system is segmented into three distinct functional parts: optimization calculation part, input plan generator, and verification part. This segmentation allows each component to be developed, maintained, and optimized independently, managing system complexity while achieving high productivity through coordinated operation of specialized modules
Solution Approach 2:
The optimization calculation part handles multiple objectives simultaneously including minimizing transfers between production lines and reducing equipment load. This multi-functionality approach consolidates what would otherwise require separate complex systems into a single unified optimization engine, reducing overall device complexity
3Productivity
If processing plans are optimized, then productivity is improved, but loss of time increases
Solution Approach 1:
The optimization calculation part generates processing plans in advance by performing optimization calculations using production plan amounts and equipment processing capacities as input data. This preliminary action allows the system to prepare optimized schedules before actual production begins, improving equipment utilization without causing time loss during execution
Solution Approach 2:
The verification part performs simulation-based appropriateness checks on generated plans to ensure they meet production requirements. By applying partial verification focused on critical aspects rather than exhaustive checking of all parameters, the system maintains high productivity while minimizing verification time
Data Source
AI summary
According to one embodiment, a generation system generates a production plan. The production plan is for producing products of product types by processes using production lines. The system includes an optimization calculation part, an input plan generator, and a verification part. The optimization calculation part generates a processing plan by an optimization calculation using first input data. The first input data includes a production plan amount of each of the product types and a processing capacity of each equipment. The input plan generator generates an input plan by using second input data. The second input data includes an input amount of workpieces to each of the production lines for each of the product types. The second input data further includes a processing route in the plurality of processes for each of the product types. The verification part determines an appropriateness of the processing plan and the input plan.