Real-Time Production Planning Under Cost and Failure Constraints
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Solution Overview
Problem
Conventional production plan management techniques fail to consider costs and failure probabilities in manufacturing processes, making it difficult to respond to sudden changes and resulting in high costs or production failures.
Innovation Solution
A production plan management device that generates real-time production plans by acquiring product order information, cost criteria, and structural constraints, using a communication unit, storage unit, and production plan generating unit to optimize manufacturing processes and minimize failure probabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional production plan management techniques are used, then production plans can be generated for a few days to several weeks, but it is difficult to quickly generate a production plan that responds to sudden plan changes
Solution Approach 1:
The production plan management device dynamically adjusts production plans in real-time based on sudden changes in manufacturing conditions. The system continuously monitors structural constraints and automatically regenerates production plans without fixed time intervals, enabling adaptive response to equipment failures, material shortages, or demand changes while maintaining optimal production scheduling.
Solution Approach 2:
The system implements real-time feedback mechanisms by continuously monitoring the manufacturing process status, structural constraints, and plan execution progress. This feedback loop enables the device to detect sudden plan changes immediately and regenerate production plans based on current conditions, ensuring rapid responsiveness while minimizing delay in plan adjustment.
2Reliability
If production plans are generated without considering costs and failure probabilities, then plan generation is simpler, but the production plan may result in high costs or failure probability
Solution Approach 1:
The system performs preliminary analysis of multiple production plan options by evaluating costs and failure probabilities before finalizing the production plan. The device pre-calculates various scenarios considering equipment failure rates, material costs, and manufacturing constraints, selecting the most reliable plan in advance while maintaining manageable system complexity through structured evaluation criteria.
Solution Approach 2:
The production plan management device incorporates cost and failure probability parameters into the plan generation process. By adjusting these parameters based on real-time manufacturing conditions, the system optimizes production plans to balance reliability with operational constraints, enabling reliable plan generation without excessive complexity through parameter-driven decision making.
Data Source
AI summary
In order to create, in real time, a production plan capable of responding to a sudden plan change in consideration of costs arising due to the production plan and a failure probability of a manufacturing process, a production plan management device includes: a communication unit configured to acquire product order information including a customer request for a first product and cost criterion information specifying a cost criterion for a budget of costs required to manufacture the first product; a storage unit configured to store at least a structural constraint database including structural constraint information specifying a structural constraint defining a condition for manufacturing processes to manufacture the first product in a factory; and a production plan generating unit configured to generate, in real time, a production plan that satisfies the customer request, the cost criterion, and the structural constraint and defines manufacturing processes for manufacturing the first product.