Spare Capacity Calculation Using Material and Process Constraints
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Solution Overview
Problem
Manufacturers face difficulties in calculating spare capacity for suppliers due to the lack of consideration for materials required in production processes, leading to inefficiencies and burdens in managing inventory variations.
Innovation Solution
A spare capacity calculation device and method that accepts inputs for process capability and material availability, calculates accumulated material numbers, and determines production capacity by considering both process and material limitations, allowing for accurate spare capacity determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the supplier reserves materials to produce a percentage of surplus to account for variation between ordered and requested parts, then the supplier can handle demand variations, but the inventory burden and cost increase
Solution Approach 1:
The system implements feedback by continuously monitoring actual order quantities versus requested quantities, and using this information to dynamically adjust production plans and material reservations. The calculation device receives feedback on actual demand patterns and adjusts the spare capacity calculation accordingly, allowing the supplier to maintain reliability while optimizing inventory levels based on real-world performance data rather than static safety margins
Solution Approach 2:
The invention changes the parameter of spare capacity calculation from a fixed percentage surplus to a dynamic value based on actual process capabilities and material availability. By adjusting the calculation parameters to reflect real-time production conditions and demand patterns, the system reduces the need for excessive inventory while maintaining the ability to handle demand variations
2Quantity of substance
If the manufacturer requests the supplier to place an order for a variable amount based on spare capacity, then the inventory burden on the supplier is reduced, but the manufacturer cannot directly calculate spare capacity without supplier involvement
Solution Approach 1:
The calculation device serves as an intermediary between the manufacturer's demand information and the supplier's production planning. It receives input data from both parties (demand forecasts, process capabilities, material availability) and performs the complex spare capacity calculation, transforming raw data into actionable production plans. This intermediary function simplifies the interaction while handling the computational complexity internally
Solution Approach 2:
The system enables self-service by allowing the supplier to independently calculate their own spare capacity using the calculation device. The supplier inputs their process capabilities and material availability data, and the system automatically computes the spare capacity without requiring manual analysis or external assistance, reducing both inventory burden and operational complexity
3Productivity
If the supplier calculates spare capacity without considering materials required for production, then the calculation is simpler, but the spare capacity cannot be accurately determined when materials are insufficient
Solution Approach 1:
The system performs preliminary action by requiring the supplier to input and register their material availability data and process capabilities in advance. The calculation device stores this information and uses it proactively in spare capacity calculations, ensuring that material constraints are considered before production decisions are made. This preliminary data preparation enables accurate calculations without adding complexity to the actual calculation process
Solution Approach 2:
The invention merges the consideration of process capabilities and material availability into a unified spare capacity calculation framework. Rather than treating these as separate factors, the system combines them into a single integrated calculation that simultaneously accounts for both production capacity and material constraints, achieving accurate results without requiring multiple separate analysis steps
Data Source
AI summary
The calculation means 82 calculates an accumulated material number by accumulating the number of materials in time series from a predetermined point in the past, and calculates the available number of materials by subtracting a cumulative production capacity accumulated up to an immediately preceding unit period among cumulative production capacities, each of which is a value obtained by accumulating a production capacity in each unit period in time series from the accumulated material number. Then, the calculation means 82 determines the smaller one of the number of products that can be produced, which is calculated based on the process capability, and the number of products that can be produced, which is calculated based on the available number of materials, as the production capacity, and accumulates the production capacities in time series from a predetermined point in the past to calculate the cumulative production capacity for each unit period.