Sensor Installation Planning for High-Variation Production Processes
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Solution Overview
Problem
The installation of sensors in cyber physical production systems (CPPS) for improving production management precision comes with costs and space considerations, necessitating a trade-off between productivity improvement and sensor installation costs.
Innovation Solution
A computer system that calculates work time variations across production processes, identifies processes requiring sensor installation based on these variations, selects appropriate sensors, and generates a display showing the processes and selected sensors for efficient productivity improvement while minimizing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are installed in all production processes to improve production management precision, then measurement precision and productivity improve, but installation cost and device complexity increase
Solution Approach 1:
The system calculates variation indexes for different production processes and selectively installs sensors only in processes with high variation indexes. This localizes the measurement function to specific areas where it is most needed, rather than uniformly deploying sensors throughout the entire production system.
Solution Approach 2:
Instead of installing sensors in all production processes (excessive action), the system identifies and installs sensors only in the necessary subset of processes that show high work time variations. This partial action approach achieves the required measurement precision while reducing overall system complexity and cost.
2Productivity
If sensors are installed in all production processes to improve productivity, then productivity improves, but installation cost increases
Solution Approach 1:
The system identifies specific production processes with high variation indexes and targets sensor installation only to those local areas. This selective approach ensures productivity improvement in critical processes while minimizing the quantity of sensors required and thus reducing installation costs.
Solution Approach 2:
The system performs partial sensor installation only in processes where it provides maximum productivity benefit, rather than implementing excessive sensor coverage across all processes. This optimizes the return on investment by focusing resources on high-impact areas.
Data Source
AI summary
A sensor installation plan is capable of improving productivity while suppressing cost necessary to install a sensor. A computer system stores information of: a process managing production processes of a product, a standard work time of the production processes, a recommended sensor used to monitor the production processes; and record information storing a first record including time necessary for production of the product and a second record including work time of the production processes. The computer system calculates work time of the production process corresponding to the second record, obtains the standard work time of the production process, calculates a variation index in works for each production process using the first record, the calculated work time, and the standard work time, identifies the production process for which installation of the sensor is necessary, and selects the sensor for the identified production process by referring to the recommended sensor information.