Production Planning Simulation for Semi-Fixed Period Reduction
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Solution Overview
Problem
In variable-mix variable-volume production, existing technologies fail to create a fluid plan by reducing the period indicated by a semi-fixed plan, despite preparation for a fixed plan being ready at its start, which hinders efficient work execution.
Innovation Solution
A production planning device that performs discrete simulations using fixed, semi-fixed, and fluid plan models to calculate a candidate period for the fluid plan, ensuring it does not overlap with the fixed plan period and is ready at the start of the fixed plan preparation time, thereby determining the fluid plan period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a semi-fixed plan is created to ensure preparation for fixed plan work is ready at the start of the fixed plan period, then reliability of fixed plan execution is improved, but the period duration increases reducing productivity
Solution Approach 1:
The patent applies dynamics by transforming the rigid semi-fixed plan into a flexible fluid plan. The simulation unit dynamically adjusts the fluid plan period based on actual resource availability and workload conditions, allowing the plan to adapt its duration and timing rather than following a fixed predetermined schedule. This enables the system to maintain preparation readiness while optimizing the actual execution period to avoid unnecessary time consumption.
2Productivity
If a fluid plan is created by reducing the semi-fixed plan period, then productivity is improved, but the complexity of plan management increases
Solution Approach 1:
The simulation unit serves as an intermediary that automatically manages the complexity of fluid plan creation. It performs discrete event simulation to calculate optimal fluid plan periods, determines resource availability, and coordinates between fixed plans and fluid plans. This intermediary handles the complex calculations and decision-making, freeing users from directly managing the complexity while still achieving productivity improvements through reduced plan periods.
3Productivity
If discrete simulation is performed to calculate optimal fluid plan periods, then productivity is improved by reducing unnecessary time, but the computational complexity and processing time increase
Solution Approach 1:
The system performs preliminary discrete simulation calculations to establish fluid plan periods before actual execution. By pre-calculating optimal periods based on historical data and resource patterns, the system avoids performing complex simulations in real-time during execution. This preliminary action captures the optimization benefits while reducing the computational burden during operational phases.
Data Source
AI summary
A production planning device (100) includes a simulation unit (106). A simulation unit (106) performs a discrete simulation based on a fixed plan model indicating a work related to a fixed plan product, which is a product, and a fixed plan period, which is a period in which the work related to the fixed plan product is performed, a semi-fixed plan model indicating a preparation period for performing the work related to the fixed plan product, and a fluid plan model indicating a work related to a fluid plan product, which is a product, so as to calculate a candidate period, which is a period not overlapping with the fixed plan period, as a candidate for a fluid plan period, which is a period in which the work indicated by the fluid plan model is performed, and when at least part of the candidate period overlaps with at least part of the preparation period and in a case where preparation for performing the work related to the fixed plan product is ready at a start time of the fixed plan period, determines the candidate period as the fluid plan period.