Setup Operation Sequencing for Multi-Line Completion Time Reduction
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Solution Overview
Problem
In high-mix low-volume production, the processing completion time is prolonged due to overlapping setup operations across multiple processing lines, where a worker cannot perform setup operations in both lines simultaneously, leading to inefficient sequencing and increased completion time.
Innovation Solution
An information processing device with an optimization engine that rearranges setup operations based on initial input orders, using a line simulator to determine the optimal sequence that minimizes processing completion time by introducing a setup determination cell to manage the workflow and prevent overlapping setup operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If setup operations are performed in the order of lines where processing operation is completed, then the initial input order is maintained, but the processing completion time becomes long
Solution Approach 1:
The system performs preliminary analysis of setup operations and their timing requirements before execution. By calculating completion times and identifying optimal sequencing in advance, the system determines the best input order that prevents setup overlaps while minimizing total processing time, rather than simply maintaining the initial input order
Solution Approach 2:
The system dynamically adjusts the input order based on real-time calculation of setup operation completions. Instead of a static input order, the system flexibly determines the optimal sequencing by considering when each line's processing will complete, allowing setup operations to be scheduled without overlaps while reducing overall completion time
2Productivity
If setup operations are overlapped across multiple lines, then processing throughput increases, but unrealistic processing completion times are generated
Solution Approach 1:
The system implements a feedback mechanism where setup operation completion times are calculated and used to control the timing of subsequent setup operations. By monitoring when setup operations complete on each line and using this information to schedule the next setup, the system ensures that setup operations are never scheduled to overlap, maintaining realistic and achievable completion times while still optimizing throughput
3Loss of time
If the order of setup operations is optimized to reduce completion time, then processing efficiency improves, but setup operations may overlap across lines
Solution Approach 1:
The system performs preliminary calculation of setup operation durations and completion times for all lines before determining the optimal input order. By analyzing the timing requirements in advance, the system identifies the sequencing that minimizes total completion time while ensuring that no setup operations overlap, thus optimizing efficiency without sacrificing coordination
Data Source
AI summary
An information processing device includes a memory, and a processor coupled to the memory and configured to rearrange setup operations with respect to an initial input order according to which products are to be input to a processing line including a plurality of lines to which a product that requires a setup operation and a processing operation is to be input, setup operations being not executed with the setup operations overlapped with each other in the plurality of lines, determine a processing completion time of the processing line based on the rearranged setup operations, and determine, as planning data, an order of setup operations that achieves a processing completion time less than a processing completion time of the initial input order among the processing completion time calculated.