Substrate Line Scheduling for Setup and Material Delivery Timing
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Solution Overview
Problem
The existing substrate production control systems fail to optimize the start timings of setup and delivery work prior to production start, leading to inconsistencies and decreased productivity due to unshared actual operation states between control devices and production managers.
Innovation Solution
A substrate production control system that includes a display section, production start timing obtaining section, schedule control section with setup and delivery time estimation, and determination sections, which consider risk margins to determine appropriate setup and delivery start timings, and a progress state control section to notify and display these timings, ensuring timely execution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the delivery work or setup work is delayed, then the substrate production line experiences long standby states, but productivity decreases
Solution Approach 1:
The system calculates and determines the optimal start timing for delivery work and setup work in advance before production begins. By computing these timings preliminarily based on production schedules and work durations, the system ensures that materials and setup activities are ready exactly when needed, preventing both delays and unnecessary standby states, thus resolving the contradiction between schedule reliability and productivity.
2Reliability
If the production progress state is delayed, then in-process inventory increases, but storage requirements increase
Solution Approach 1:
The system shares actual operation states and production progress information between multiple control devices and production managers in real-time. This feedback mechanism allows all stakeholders to monitor the current status and adjust their actions accordingly, ensuring that delivery and setup work are synchronized with actual production progress, thereby preventing excessive in-process inventory accumulation while maintaining schedule accuracy.
3Device complexity
If start timing of delivery work and setup work is determined based on production schedule only, then scheduling is simple, but actual operation state sharing is insufficient
Solution Approach 1:
The system implements a universal information sharing platform that serves multiple functions: calculating optimal timings, sharing actual operation states, notifying relevant personnel, and coordinating between different control devices. This multi-functional approach consolidates various information management tasks into a single system, reducing overall complexity while comprehensively addressing information loss through centralized real-time sharing.
Data Source
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AI summary
Substrate production control system (1) includes production start timing obtaining section (41) configured to obtain information of production start timing (Sp) when production of a substrate is started on substrate production lines (91, 92, and 93), setup time estimation section (42) configured to estimate setup times (Td1 and Td2) required for a setup work of setting up the substrate production line, setup start timing determination section (43) configured to determine setup start timing (Sd) of starting the setup work based on the production start timing and the setup time, delivery time estimation section (44) configured to estimate delivery time (Ts) required for a delivery work of receiving a member necessary for production of the substrate from member warehouse (95) and conveying the member to at least one of an execution location (external setup area 94) of the setup work and the substrate production line, and delivery start timing determination section (45) configured to determine delivery start timing (Ss) of starting the delivery work based on the setup start timing and the delivery time.