Substrate Line Scheduling for Synchronized Setup and Material Delivery
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Solution Overview
Problem
Conventional substrate production control systems lack synchronization in start timings for setup and delivery work before production starts, leading to inconsistencies and decreased productivity due to delayed operations and in-process inventory.
Innovation Solution
A substrate production control system that includes sections for obtaining production start timing information, estimating setup and delivery times, and determining optimal start timings for setup and delivery work based on these estimates, ensuring timely execution and minimizing delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the start timing of delivery work and setup work is determined based on production schedule alone, then production plan is simple to manage, but actual operation state is not shared causing inconsistency in substrate production schedule
Solution Approach 1:
The system implements feedback mechanisms where control devices report actual operation states (delivery work progress, setup work progress, production progress) to a central management system. This feedback loop enables real-time synchronization between planned and actual schedules, ensuring consistency across multiple control devices and production managers without increasing management complexity.
Solution Approach 2:
A central schedule management system acts as an intermediary between production schedule, delivery work control, and setup work control. This intermediary coordinates information flow and synchronizes timing across different work streams, resolving inconsistencies while maintaining simple individual device operations.
2Adaptability or versatility
If delivery work or setup work for next substrate type is delayed, then schedule flexibility is maintained, but substrate production line enters long standby state decreasing productivity
Solution Approach 1:
The system performs preliminary actions by calculating and determining the start timing of delivery work and setup work in advance, based on production start timing and estimated durations. This preliminary scheduling ensures that all preparatory activities are synchronized and completed before production begins, eliminating standby states while maintaining schedule flexibility through coordinated timing.
Solution Approach 2:
The system ensures continuity of useful action by synchronizing delivery work, setup work, and production operations so that no idle time occurs between工序. By calculating optimal start timings and coordinating execution, the system maintains continuous productive operation without interruptions or standby states.
3Adaptability or versatility
If production progress of current substrate type is delayed, then production adaptability is maintained, but member for next substrate type remains as in-process inventory increasing waste
Solution Approach 1:
The system uses feedback from actual production progress to dynamically adjust and synchronize the timing of delivery and setup work. When production progress changes, the system receives this information and recalculates optimal timings, ensuring that members are delivered and setup is completed exactly when needed, minimizing in-process inventory while maintaining production adaptability.
Solution Approach 2:
The system enables self-service by allowing the schedule management to automatically coordinate delivery and setup operations based on real-time production status. The system self-adjusts timing without external intervention, ensuring that members are supplied precisely when production requires them, eliminating unnecessary inventory accumulation.
Data Source
AI summary
A substrate production control system includes production start timing obtaining section configured to obtain information of production start timing on substrate production lines, setup time estimation section configured to estimate setup times required for a setup work of setting up the substrate production line, setup start timing determination section configured to determine setup start timing of starting the setup work based on the production start timing and the setup time, delivery time estimation section configured to estimate delivery time required for a delivery work of receiving a member necessary for production of the substrate from member warehouse and conveying the member to at least one of an execution location (external setup area) of the setup work and the substrate production line, and delivery start timing determination section configured to determine delivery start timing of starting the delivery work based on the setup start timing and the delivery time.