Production Plan Reconfiguration for Plan-Actual Deviations
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Solution Overview
Problem
Conventional production management systems struggle to achieve target production efficiency when deviations occur between planned and actual production results, particularly in high-mix low-volume production scenarios, due to insufficient consideration of resource allocation and operation control impacts on overall product manufacture.
Innovation Solution
A production management device that generates change proposals for production, process, and resource control plans by using product production plan, process plan, and resource control information, adjusting these plans if deviations are detected to optimize key performance indicators such as manufacturing cost and production throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If only the production plan is changed to follow actual production results, then the deviation between plan and actual results is reduced, but the target production efficiency cannot be achieved due to insufficient consideration of resource allocation and operation control impacts
Solution Approach 1:
The patent segments the production management system into three distinct but interconnected components: production plan information, process plan information, and resource control information. This segmentation allows each component to be optimized independently while maintaining overall coordination, enabling the system to achieve both reduced deviation and target production efficiency through coordinated optimization of all three elements rather than merely adjusting the production plan in isolation.
Solution Approach 2:
The patent merges the optimization of production plan, process plan, and resource control information into a unified management approach. By combining these three elements and optimizing them together based on their interrelationships, the system achieves comprehensive optimization that simultaneously reduces deviation between plan and actual results while maintaining target production efficiency, overcoming the limitation of single-component adjustment.
2Productivity
If work assignment is changed to use robots instead of persons, then labor efficiency is improved, but work delay and equipment failure increase due to lack of review on operation control information
Solution Approach 1:
The patent implements feedback mechanisms by reviewing resource control information (which includes operation control data for robots and other production resources) alongside production plan and process plan information. This feedback loop enables the system to identify potential work delays and equipment failures before they occur, allowing for preventive measures to be taken while maintaining the labor efficiency benefits of automation.
Solution Approach 2:
The patent performs preliminary review and optimization of resource control information before actual production execution. By analyzing operation control information in advance and adjusting resource allocation and control parameters proactively, the system prevents work delays and equipment failures from occurring, ensuring reliable automated production while maintaining high labor efficiency.
3Adaptability or versatility
If production resources are reassigned to varieties in high-mix low-volume production, then customization capability is improved, but deviation between production plan and actual results increases due to increased complexity
Solution Approach 1:
The patent applies dynamic optimization by continuously adjusting production plan, process plan, and resource control information based on real-time production status and actual results. This dynamic approach enables the system to adapt to the complexity of high-mix low-volume production and customization requirements while maintaining accurate plan-actual alignment through continuous coordination and adjustment of all three information elements.
Solution Approach 2:
The patent utilizes parameter changes by optimizing multiple variables across production plan, process plan, and resource control information simultaneously. By changing and coordinating multiple parameters together rather than single-parameter adjustment, the system achieves both high adaptability for customization and precise deviation control in complex high-mix low-volume production environments.
Data Source
AI summary
If a deviation occurs between a production plan and actual production results, a change proposal is generated for a more appropriate production plan, process plan, and resource control information by a production management device. Product production management is performed using product production plan information, process plan information pertaining to the product production processes, and resource control information defining the operation of production resources, which are manufacturing equipment. If a deviation occurs between the product production plan and actual production results that indicate the progress of production, in the course of the production management carried out using the first production plan information, the first process plan information, and the first resource control information, a determination is made to use a second process plan information and second resource control information, which are different from the first process plan information and the first resource control information.