Production Progress Control With Delay-Based Plan Switching
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Solution Overview
Problem
Existing methods fail to accurately predict project completion dates and prevent productivity loss due to process delays, leading to potential delivery date delays that cannot be mitigated once a certain time has elapsed.
Innovation Solution
A progress management system that includes a control unit to predict delays and generate changing proposals for production plans, adjusting operations to maintain productivity by switching to alternative schedules when delays occur.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the production plan is reviewed after a certain time has elapsed, then the delay alarm can be detected, but the ability to prevent delivery date delay is lost because there is no time left to adjust the plan
Solution Approach 1:
The system performs preliminary actions by predicting productivity and generating changing proposals in advance, before the actual delay occurs. The control unit predicts productivity for various delay scenarios and prepares alternative production plans beforehand, enabling timely intervention when delays are detected without losing response time.
Solution Approach 2:
The system implements continuous feedback by monitoring actual progress against the production plan, comparing it with predicted productivity under delay conditions, and automatically generating changing proposals when deviations are detected. This closed-loop feedback mechanism ensures early detection and immediate response to potential delays.
2Reliability
If the production plan is adjusted frequently to respond to delays, then delivery date can be maintained, but the complexity of plan management increases
Solution Approach 1:
The system performs self-service by automatically predicting productivity impacts, generating changing proposals, and determining switching timings without requiring manual intervention. The control unit autonomously analyzes delay scenarios, creates alternative plans, and identifies optimal switching points, reducing the complexity of plan management while maintaining delivery date guarantees.
3Loss of time
If the completion date and time are predicted early, then the influence on productivity can be estimated in advance, but accurate prediction cannot be made unless the process progresses to some extent
Solution Approach 1:
The system applies partial action by predicting productivity for specific delay amounts rather than attempting to predict the complete final outcome early. It generates changing proposals for various hypothetical delay scenarios, allowing early identification of potential issues without requiring complete process progress for accurate baseline predictions.
Data Source
AI summary
A progress management system has a control unit and a storage unit, which holds a production plan for one or more products. The production plan includes, for the operation of each process for producing each of the products: the allocation of the operation of the process to equipment; scheduled start and end times for the operation of the process; and a scheduled end time for the operation of the process. The control unit predicts, on the basis of the production plan, productivity for the case in which the operation of the process is delayed, and, on the basis of the delay amount of the operation of the process for the case in which it is predicted that the productivity will not satisfy a predetermined standard. The control unit generates a changing proposal for the production plan and a switching timing to the changing proposal for the production plan such.