Work Device Allocation Using Simulation Wait-Time Indices
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Solution Overview
Problem
Existing manufacturing line systems face inefficiencies in managing the number of work devices to meet desired Key Performance Indicators (KPIs) such as work completion time and cost, particularly when handling a variety of products in small quantities, leading to increased standby times and manufacturing costs.
Innovation Solution
A non-transitory computer-readable medium storing a specifying program that optimizes the distribution of objects to work devices by simulating different processing orders and counting indices N1 and N2 to determine the necessity of adding or removing work devices, thereby adjusting the number of devices to satisfy predetermined KPI conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of work devices is increased to meet desired KPIs, then productivity is improved, but manufacturing cost increases
Solution Approach 1:
The system performs simulation and evaluation of different work device configurations before actual implementation. By calculating indices N1 and N2 in advance and evaluating them against thresholds, the optimal number of work devices is determined beforehand, avoiding both over-provisioning (wasting resources) and under-provisioning (causing delays), thus resolving the contradiction between productivity improvement and cost control
2Productivity
If simulation and evaluation processing is performed for all work devices, then manufacturing efficiency is improved, but processing time increases
Solution Approach 1:
The evaluation process is segmented into distinct phases: simulation phase where work devices are virtually tested, index calculation phase where N1 and N2 are computed, and evaluation phase where thresholds are compared. This segmentation allows parallel processing and optimization of each phase, reducing overall processing time while maintaining comprehensive evaluation of manufacturing efficiency
Solution Approach 2:
Instead of physically testing different work device configurations, the system creates virtual copies through simulation. The simulation reproduces manufacturing scenarios digitally, allowing rapid evaluation of multiple configurations without actual physical trials, thus significantly reducing processing time while maintaining evaluation accuracy
Data Source
AI summary
A computer-readable recording medium storing a specifying program for causing a computer to perform processing including: obtaining first information indicating an order of processing a plurality of objects; obtaining second information indicating a type being processable by each work device; obtaining a result of a simulation regarding processing of the work devices; counting a number N1 of objects having moved to another work device although processing is capable of being executed on an object to be distributed next, and counting a number N2 of objects being caused to wait since processing is executed on another object although processing is capable of being executed on the object to be distributed next, under conditions such that each object waits when the work device executes processing on another object; and specifying a work device to be increased or decreased, according to any of the number N1 or the number N2.