Production Plan Apparatus for Delay Visualization
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Solution Overview
Problem
Manufacturing plants face challenges in creating production plans that effectively manage delays and prioritize product takeoffs to meet customer delivery deadlines, as existing systems struggle to accurately assess and adjust production line throughput and lead times to avoid delays.
Innovation Solution
A production plan apparatus that sets multiple takeoff objectives with different priorities based on production line throughput and lead times, calculates production plan data to satisfy these objectives, and displays delay information to facilitate adjustments and optimize production scheduling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If computer arithmetic processing is used to calculate production plans based on lead time and throughput, then production plan data can be obtained, but delay of takeoff quantity from takeoff objective occurs due to throughput restrictions and lead time constraints
Solution Approach 1:
The system calculates delay degrees for multiple takeoff objectives and provides feedback to operators through display. This feedback mechanism allows operators to understand the impact of production plan adjustments on different takeoff objectives, enabling them to make informed decisions to recover from delays while considering the influence on subsequent takeoff objectives.
Solution Approach 2:
The system pre-calculates and displays delay degrees for multiple takeoff objectives before operators make adjustments. By showing the potential impact of delays in advance, operators can take preliminary actions to adjust production plans proactively rather than reactively, preventing further delays from propagating through the production schedule.
2Reliability
If operators manually adjust production plans to recover from delays, then takeoff objectives can be recovered, but the complexity of considering throughput at next steps and lead time margins increases operational burden
Solution Approach 1:
The system acts as an intermediary between production plan data and operator decision-making. It automatically calculates and displays delay degrees for multiple takeoff objectives, serving as a mediator that translates complex production data into actionable insights. This reduces the cognitive burden on operators while maintaining the reliability of takeoff objective recovery.
Solution Approach 2:
The system replaces manual mechanical calculation and analysis with automated computer-based calculations. Instead of operators manually analyzing throughput restrictions and lead time margins, the system automatically computes delay degrees and presents them for operator review, reducing operational complexity while improving accuracy.
3Ease of operation
If production plan data is displayed without delay information, then simple display is maintained, but operators cannot accurately assess the degree of delay from takeoff objective
Solution Approach 1:
The system uses color-coded display to represent different delay degrees for multiple takeoff objectives. By visually encoding delay information through color changes, the system maintains display simplicity while providing accurate delay assessment. Operators can quickly grasp the severity of delays without complex numerical data, achieving both simplicity and precision.
Data Source
AI summary
A plurality of takeoff objectives are set based on a takeoff request with respect to a target step in production lines, at least throughput of each production line, and basic information of a production plan for each production line, production plan data satisfying the plurality of takeoff objectives is obtained, takeoff objective delay data indicating that the production plan data is delayed with respect to the plurality of takeoff objectives is obtained, and at least a degree of delay of the product is displayed based on the production plan data and the takeoff objective delay data in accordance with each of the plurality of takeoff objectives in a preset display conformation.