Integrated Production Planning With Real-Time Maintenance Feedback
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Solution Overview
Problem
Current production and maintenance planning systems in basic industry plants lack automatic and automated consideration of real-time component states and maintenance data, leading to suboptimal adjustments and rescheduling due to unforeseen disruptions, relying heavily on manual entries and empirical values.
Innovation Solution
Integration of a networked system that connects the automation system, production planning system, condition monitoring system, quality determination system, and maintenance planning system via interfaces, allowing for the automatic consideration of real-time component states and production data to optimize production and maintenance planning, enabling dynamic adjustments and improved resource allocation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If production and maintenance planning systems operate independently with manual data entry, then system complexity is reduced, but planning accuracy and responsiveness to real-time component states deteriorate
Solution Approach 1:
The patent merges previously independent production planning and maintenance planning systems into an integrated system that automatically shares data and coordinates planning. The production planning system receives maintenance planning data and adjusts production schedules automatically, eliminating manual data entry while improving planning accuracy through real-time component state information.
Solution Approach 2:
The integrated system implements feedback loops where the condition monitoring system continuously provides real-time component state data to both production and maintenance planning systems. This feedback enables automatic adjustments to production schedules based on actual component conditions, significantly improving planning accuracy without requiring complex manual intervention.
2Extent of automation
If manual data entry and empirical values are used for planning, then automation extent is reduced, but implementation complexity and cost decrease
Solution Approach 1:
The patent creates a universal integrated planning system that handles both production and maintenance planning through a common architecture. This multi-functional system automatically processes component state data, generates coordinated schedules, and adjusts plans in real-time, significantly increasing automation level while managing implementation complexity through standardized interfaces and data structures.
Solution Approach 2:
The system implements self-service capabilities where the integrated planning system automatically adjusts production schedules based on real-time maintenance needs and component states without manual intervention. The system autonomously coordinates between production and maintenance requirements, reducing the need for manual data entry and empirical estimations while maintaining high automation levels.
3Adaptability or versatility
If production schedules are adjusted manually due to unforeseen disruptions, then adaptability is reduced, but response time and operational overhead decrease
Solution Approach 1:
The patent implements preliminary action by pre-establishing the integrated system architecture and data communication pathways before disruptions occur. When unforeseen disruptions happen, the system is already configured to automatically receive real-time component state data and adjust schedules instantly, eliminating manual rescheduling delays while maintaining high adaptability to changing conditions.
Solution Approach 2:
The system dynamically adjusts production schedules in real-time based on actual component states and maintenance needs. The integrated planning system continuously monitors component conditions and automatically modifies production plans to accommodate maintenance requirements, enabling rapid adaptation to disruptions without manual intervention and significantly reducing rescheduling time.
4Productivity
If real-time component state data is integrated into planning systems, then productivity is improved, but information processing requirements and system complexity increase
Solution Approach 1:
The patent extracts only the essential real-time component state data needed for planning decisions from the condition monitoring system. The integrated planning systems process selectively extracted information about component wear, maintenance needs, and operational status, reducing data processing load while maintaining high productivity through focused analysis of critical parameters rather than processing all available sensor data.
Data Source
Figure 1
Figure 2~4
AI summary
The invention relates to a production planning system (6) for a raw materials industry plant (ANL), which determines the production planning data (Pi) thereof and specifies said data to the automation system (1) of the plant (ANL). A state monitoring system (7) determines previous and future anticipated states (Z1) of components of the plant (ANL). A quality determination system (8) determines states (Z2) of starting products (Ai) produced and still to be produced by the plant (ANL) and/or past and future states (Z3) of the plant (ANL) as a whole. A maintenance planning system (9) and/or the production planning system (6) receive, from the state monitoring system (7), the states (Z1) of the components of the plant (ANL), determined by the state monitoring system (7) and, from the quality determination system (8), the states (Z2 and Z3) of the starting products (Ai) and/or of the plant (ANL) as a whole, determined by the quality determination system (8). They consider the data received from the state monitoring system (7) and from the quality determination system (8) in the determination of maintenance planning data (W) and/or the production planning data (Pi).