Production Planning System with Fixed Setup Time Intervals

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Solution Overview

Problem

In production planning, short-term changes in process sequences due to feedback from actual execution can lead to unpredictable and unreliable scheduling, causing process backlogs and frequent adjustments in setup times, which complicates planning and execution.

Innovation Solution

A system and method that plan production processes by accounting for setup times dependent on predecessor process information, with defined time intervals where setup times are held constant, independent of predecessor processes, ensuring predictable and reliable short-term planning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If setup times are dynamically adjusted based on predecessor process information and execution feedback, then production planning adaptability is improved, but planning stability and predictability deteriorate

Engineering Contradiction:

Improvesetup time adaptabilityVSAvoidplanning stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The planning horizon is segmented into different time intervals with distinct characteristics. Short-term intervals maintain fixed setup times for stability, while long-term intervals allow dynamic adjustments for adaptability. This segmentation resolves the contradiction by applying different rules to different time segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically switches between fixed and variable setup time modes based on the time interval. In the short term, setup times are fixed to ensure stability; in the long term, they become variable to accommodate changes. This dynamic behavior allows the system to optimize for both stability and adaptability at different times.

Inventive Principle:

Principle #15Dynamics

2Speed

If processes are automatically rescheduled based on execution feedback, then production responsiveness is improved, but planning reliability deteriorates

Engineering Contradiction:

Improveprocess confirmation speedVSAvoidplanning reliability

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The system performs preliminary scheduling with fixed setup times to establish a reliable baseline plan. Automatic rescheduling is then limited to adjustments that maintain the overall sequence integrity, preventing unreliable changes while allowing necessary corrections. This preliminary action ensures reliability before any adjustments are made.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates feedback mechanisms that trigger automatic rescheduling only when necessary and within defined constraints. The feedback loop maintains planning reliability by ensuring that adjustments do not fundamentally change the sequence, while still responding to execution variations. This controlled feedback approach balances responsiveness with reliability.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If sequence dependent setup times are adjusted after each process confirmation, then execution accuracy is improved, but planning complexity increases

Engineering Contradiction:

Improveexecution accuracyVSAvoidplanning complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The adjustment process is segmented into discrete steps: first establishing the base sequence with fixed setup times, then making controlled adjustments only when confirmed processes require changes. This segmentation reduces complexity by limiting adjustments to specific moments rather than continuously recalculating everything.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system applies partial adjustments to setup times only when necessary, rather than adjusting all setup times uniformly. This partial action approach maintains execution accuracy for affected processes while avoiding the complexity of recalculating the entire schedule, thus balancing precision with planning complexity.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS7454260B2Systems and methods for production planning with sequence independent setup activities

Publication Date: 2008.11.18 SAP SE

AI summary

Systems, methods, and computer program products are provided for planning production processes. In one implementation, a method is provided that includes the steps of planning a sequence of processes running on a resource, where the planning takes into account setup times for the resource for a process depending at least on predecessor process information, storing the sequence of processes, and defining time intervals for the resource within which setup times for processes are held constant independently of the predecessor process information.