Production Queue Visualization Using Retention Increase Rates
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Solution Overview
Problem
In production management systems, visualizing the appropriateness of retention numbers is challenging due to intentional stock preparation, lack of fluctuation detection, early cause identification, and varying reference values across steps, leading to inefficient facility operational availability management.
Innovation Solution
Calculating and visualizing the retention increase rate and acceleration rate using a holistic chart with a common reference value, where the display mode depends on the retention increase rate and acceleration rate, facilitating early detection of abnormalities and optimal facility management without requiring new information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If retention number exceeds reference value, then abnormality is detected, but false positives occur when intentional stock preparation exceeds threshold
Solution Approach 1:
The patent changes the parameter from monitoring absolute retention number to monitoring retention increase rate (derivative parameter). This transforms the detection metric from a static threshold-based approach to a dynamic rate-of-change approach, allowing intentional stocks to be distinguished from abnormal accumulation since intentional stocks typically don't show continuous increase.
Solution Approach 2:
The system performs preliminary calculation of retention increase rate before abnormality detection. By pre-calculating the rate of change and comparing it against reference rates, the system prepares the data in a form that enables more accurate anomaly detection, distinguishing between planned inventory buildup and unexpected retention issues.
2Reliability
If retention number is monitored at each time point, then continuous abnormality detection is achieved, but early cause identification is delayed
Solution Approach 1:
The system pre-calculates and stores retention increase rates for each time point and step before actual monitoring begins. This preliminary preparation of derivative data enables immediate comparison and anomaly detection when production data becomes available, eliminating the need to wait for multiple time points to accumulate before detecting trends.
Solution Approach 2:
The system implements continuous feedback by comparing real-time retention increase rates against pre-established reference rates. When deviations are detected, the system immediately identifies potential abnormalities and can trigger alerts, creating a closed-loop monitoring system that provides timely feedback for rapid response.
3Measurement precision
If different reference values are set for each step, then appropriateness is accurately evaluated, but system complexity increases
Solution Approach 1:
The patent establishes a universal reference value system where a single reference retention increase rate can be applied across multiple steps. This universal approach simplifies management while remaining effective because it focuses on the rate of change rather than absolute values, allowing the same reference to work for different production steps with varying characteristics.
Solution Approach 2:
By transforming the monitoring parameter from absolute retention number to retention increase rate, the system enables use of a common reference value across different steps. The derivative parameter normalizes the data in a way that makes universal comparison valid, reducing the need for step-specific calibration while maintaining evaluation accuracy.
4Quantity of substance
If facilities are increased to reduce stocks in work queue, then retention is reduced, but facility utilization efficiency decreases
Solution Approach 1:
The system provides continuous feedback on retention increase rates to production managers, enabling data-driven decisions about facility allocation. By monitoring when and where retention rates deviate from references, the system identifies specific bottlenecks that require facility intervention, allowing targeted facility deployment rather than blanket increases, thus maintaining high utilization efficiency while reducing unnecessary stocks.
Solution Approach 2:
The system enables dynamic adjustment of facility operations based on real-time retention monitoring. When retention increase rates indicate bottlenecks, facilities can be dynamically reallocated to affected steps. This dynamic responsiveness allows the system to reduce stocks in work queue without permanently increasing facility count, maintaining high utilization efficiency through flexible resource allocation.
Data Source
AI summary
Production past record information showing the execution time point of each step is accumulated for each product loaded in a production system. A supporting system calculates, for each step, a retention increase rate at each time point on the basis of the production past record information. The “retention increase rate” is an amount of increase in retention number per unit time. The supporting system displays a holistic chart for a production situation, which has a time axis and a step axis (axis perpendicular to the time axis and corresponding to steps). A display mode of each position in the holistic chart depends on whether a retention increase rate for the time point and step corresponding to the position is a negative value, zero, or a positive value, and a difference between the retention increase rate and a rate reference value (a reference value for the retention increase rate).