Rule-Engine Production Planning for Automated BOP Generation
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Solution Overview
Problem
Manual generation of production plans, such as bills of process (BOP), is inefficient, error-prone, and lacks scalability, particularly in environments with rapid product changes and decreasing lot sizes, leading to increased operational costs and reduced productivity.
Innovation Solution
A computer-implemented method using a rule engine to generate a production plan (BOP) by matching product and production characteristics with library elements, enabling automated creation and synchronization with control programs for manufacturing machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual generation of production plans is used, then flexibility in creating production plans is maintained, but efficiency and productivity deteriorate due to time-consuming processes and errors
Solution Approach 1:
The patent replaces manual mechanical processes with an automated rule engine system. The rule engine automatically generates and updates production plans, bills of materials, and work instructions by processing product data and applying predefined rules, eliminating the need for manual creation and updating of these documents.
Solution Approach 2:
The system enables self-service automation where the rule engine autonomously generates production plans and related documents without human intervention. The automated system serves itself by automatically updating all necessary production documents when product changes occur, without requiring manual input from planners or engineers.
2Reliability
If manual updating of production documents is performed, then adaptability to product changes is possible, but reliability deteriorates due to human errors and lack of synchronization
Solution Approach 1:
The patent implements feedback mechanisms where the rule engine continuously monitors product data changes and automatically updates production plans, bills of materials, and work instructions in real-time. This closed-loop system ensures that all production documents remain synchronized and accurate by detecting changes and triggering automatic updates.
Solution Approach 2:
The system performs preliminary actions by pre-configuring rules and templates that automatically generate correct production documents before actual production begins. The rule engine is预先 equipped with manufacturing rules, standards, and templates that enable it to automatically create accurate production plans and related documents without manual intervention.
3Adaptability or versatility
If integrated production planning systems are implemented, then scalability and visibility improve, but device complexity increases
Solution Approach 1:
The patent segments the production planning system into modular components: a rule engine for processing logic, a template system for document structure, and automated generation modules for different document types. This segmentation allows the system to scale by adding or modifying individual modules without redesigning the entire system, managing complexity through modular architecture.
Solution Approach 2:
The rule engine serves multiple functions by generating production plans, bills of materials, and work instructions using the same core engine and rule set. This universal approach allows the system to handle various production planning tasks with a single integrated platform, improving scalability without proportionally increasing complexity.
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
A method, (e.g., a computer-implemented method), of generating a production plan (BOP) is provided. The method includes obtaining one or more product and/or production characteristics (E-BOM, CAD-BOM, M-BOM), (e.g., a production content, a production time, and/or a production quantity, for example in a E-BOM, M-BOM, and/or CAD file format), for a product to be manufactured. The method further includes determining, by a rule engine (10), based on the characteristics one or more library elements from a plurality of library elements (11a, 11b), wherein each library element includes one or more process descriptions relating to the characteristic. The method further includes arranging, by the rule engine (10), the one or more process descriptions into a production plan (BOP).