Production Simulation Modeling for Accurate Bottleneck Diagnosis
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Solution Overview
Problem
Current methods for diagnosing bottlenecks in production systems rely on simple comparisons and experience-based estimations, leading to inaccurate operation rate determination and inefficient resource allocation, resulting in underutilization or overutilization of production capacity.
Innovation Solution
A method and device that utilize a simulation model to identify bottlenecks and determine operation rates by connecting simulation modules based on production system flow, optimizing models with maintenance parameters, and dynamically simulating the system to monitor abnormal states and adjust parameters for accurate bottleneck identification and rate determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If simple comparison method is used to diagnose bottleneck link, then diagnosis process is simple, but diagnosis accuracy is low
Solution Approach 1:
The patent segments the production system into multiple process links and introduces buffer modules between them. Each link is independently modeled and simulated, allowing precise identification of bottleneck locations through monitoring buffer states rather than simple overall comparison.
Solution Approach 2:
The patent introduces buffer modules as intermediary elements between process links. These buffers act as mediators that accumulate workpieces and provide observable states (full/empty) that reveal bottleneck information, transforming indirect comparison into direct observation.
2Stability of the object's composition
If conservative operation rate with surplus coefficient is set, then production smoothness is ensured, but investment efficiency decreases
Solution Approach 1:
The patent performs preliminary simulation and optimization before actual production to determine the accurate operation rate. By pre-modeling the production system and identifying bottlenecks through simulation, the optimal operation rate is established in advance, eliminating the need for conservative surplus coefficients during actual operation.
Solution Approach 2:
The patent uses simulation feedback to continuously refine the operation rate determination. The simulation model provides feedback on system performance under different operation rates, allowing optimization of the operation rate to balance production smoothness with investment efficiency.
3Productivity
If operation rate is estimated through experience and formulas, then determination process is quick, but operation rate accuracy is low
Solution Approach 1:
The patent creates a virtual copy (simulation model) of the production system that replicates its behavior. This digital twin allows accurate operation rate determination through simulation experiments, replacing inaccurate experience-based estimation while maintaining quick determination through computational efficiency.
Data Source
AI summary
The invention provides a method and a device for controlling a production system based on a simulation model, belonging to the technical field of industrial process control. The main purpose of the invention is to improve the accuracy of identifying bottlenecks in the production system through a simulation model and to solve the problem that the existing operation rate obtained by simple estimation based on experience has a large error. The method comprises the following steps: connecting simulation modules based on the process flow of the production system to generate an initial simulation model, and optimizing the initial simulation model based on the maintenance parameters of the production system to obtain an optimized simulation model; Based on the optimized simulation model, identify the bottleneck of the production system or determine the operation rate of the production system.