Production System Program Switching via Kanban and Line-Specific Storage
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Solution Overview
Problem
Existing production systems face errors during program switching when producing multiple types of boards, as program information is not stored specifically for each production line, leading to potential errors during large-scale program changes.
Innovation Solution
A production system with a Kanban information management table and product information management table that stores programs for each combination of product name and production line, allowing for the acquisition and automatic switching of programs based on Kanban information, ensuring accurate program execution across multiple production lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If program information is not stored for each production line, then the system structure is simpler, but program switching errors occur when a large number of programs are switched
Solution Approach 1:
The patent segments the program storage structure by creating separate program information records for each production line. The program storage unit stores program information associated with both production line identifiers and program identifiers, allowing distinct program configurations for each production line. This segmentation eliminates program switching errors by ensuring each production line has its own accurate program information.
Solution Approach 2:
The patent adds a production line dimension to the program storage structure. Instead of storing programs in a single flat structure, the system now stores programs with dual indexing: by production line and by program type. This dimensional expansion allows the system to retrieve the correct program for the specific production line, preventing switching errors while maintaining organizational clarity.
2Productivity
If programs are manually switched for each production line, then program accuracy can be verified, but the switching process becomes time-consuming and less efficient
Solution Approach 1:
The patent implements a feedback mechanism where the program switching means automatically retrieves program information from the program storage unit based on production line identifiers, verifies the retrieved programs against the required program list, and only then transmits the correct programs to the production facilities. This automated verification feedback loop ensures both speed and accuracy in program switching.
Solution Approach 2:
The program storage unit acts as an intermediary between the program list acquisition means and the production facilities. It stores and manages program information for multiple production lines, allowing the system to automatically retrieve and transmit the correct programs without manual intervention, thereby improving both switching speed and reliability.
3Reliability
If a unified program storage system is used for all production lines, then data management is simpler, but errors occur when switching programs across different production line structures
Solution Approach 1:
The patent segments the unified program storage system into production line-specific records. Each record in the program storage unit is associated with a specific production line identifier, allowing the system to retrieve programs tailored to each production line's structure and requirements. This segmentation prevents errors caused by using incorrect programs on specific production lines.
Solution Approach 2:
The patent applies local quality by storing program information that is specific to each production line's characteristics. The program storage unit maintains distinct program configurations for each production line, ensuring that each production line receives programs appropriate to its specific structure and capabilities, thereby improving execution accuracy.
Data Source
AI summary
A production system acquires a program list on the basis of Kanban information and switches programs of production facilities and a program switching method used in the production system are disclosed. The production system includes: program list acquisition means for acquiring a product name from a Kanban information management table and acquiring a program list corresponding to a combination of the acquired product name and a production line name from a product information management table; and program switching means for searching for a corresponding program from a program storage unit on the basis of the program list acquired by the program list acquisition means, transmitting the searched program to each production facility of a plurality of production lines, and switching the program.