Work-in-process Management Control System for Manufacturing Bottlenecks
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Solution Overview
Problem
In automatic manufacturing environments, productivity imbalances between processes lead to work-in-process accumulation, reducing transfer efficiency and increasing production waste due to unbalanced distribution and storage limitations.
Innovation Solution
A work-in-process management control method and system that sets control thresholds based on device and storage capacities to manage the shifting of work-in-process, preventing overloading and optimizing storage by shifting to reservoirs with available space, thereby maintaining balanced work-in-process levels and improving transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If work-in-process is accumulated in process devices and storage devices to handle productivity imbalance, then the ability to buffer productivity differences is improved, but transfer efficiency decreases and production waste increases
Solution Approach 1:
The control device monitors the quantity of work-in-process in each supply reservoir in real-time and compares it against preset thresholds. When the quantity exceeds the upper threshold, the system automatically responds by controlling process devices to stop producing or by transferring excess work-in-process to other reservoirs. This closed-loop feedback mechanism dynamically adjusts production flow to maintain optimal work-in-process levels, preventing both over-accumulation and excessive transfer operations, thereby resolving the contradiction between buffering capability and transfer efficiency
Solution Approach 2:
The system dynamically adjusts the work-in-process quantity in supply reservoirs based on real-time production conditions. By setting adjustable upper and lower thresholds and automatically responding when these thresholds are breached, the system creates a dynamic balance that adapts to changing productivity conditions across different processes. This dynamic control ensures work-in-process is maintained at optimal levels without requiring excessive accumulation or frequent transfers
2Productivity
If work-in-process is accumulated in supply reservoirs to ensure continuous production, then device utilization is improved, but storage space is exhausted and transfer difficulty increases
Solution Approach 1:
The control device continuously monitors work-in-process quantities in supply reservoirs and implements feedback control. When the quantity reaches the upper threshold, the system responds by either halting production in preceding processes or initiating transfers to reduce the quantity below the threshold. When the quantity drops to the lower threshold, production resumes or new work-in-process is introduced. This feedback mechanism ensures reservoirs maintain optimal levels for continuous operation without overfilling, thereby preventing transfer difficulties while maintaining high device utilization
Solution Approach 2:
The system performs preliminary actions by presetting upper and lower thresholds for work-in-process quantities before production imbalances occur. These pre-established control parameters enable the system to proactively respond to potential storage exhaustion or transfer issues by maintaining work-in-process within optimal ranges, preventing the need for complex emergency transfer operations
3Duration of action of stationary object
If excessive work-in-process is stored in factories to maintain production flow, then production continuity is improved, but liquid assets are reduced and market response sensitivity decreases
Solution Approach 1:
The control device implements real-time feedback monitoring of work-in-process quantities across the manufacturing system. By continuously comparing actual quantities against preset thresholds and automatically responding through production adjustment or inter-reservoir transfer, the system maintains the minimum necessary work-in-process levels to ensure production continuity. This prevents excessive accumulation that would extend turnaround periods while avoiding production interruptions, thereby optimizing the balance between production continuity and asset efficiency
Solution Approach 2:
The system dynamically adjusts the work-in-process quantity parameters in supply reservoirs based on real-time production conditions and threshold comparisons. By changing the work-in-process level parameter within optimal ranges defined by upper and lower thresholds, the system ensures sufficient inventory for production continuity while preventing excessive storage that would increase turnaround periods and reduce asset efficiency
Data Source
AI summary
The present disclosure relates to a work-in-process management control method and a work-in-process management control system using the work-in-process management control method. The work-in-process management control method includes: receiving, from first process devices that execute a first process, an out-of-process request for work-in-process; determining whether a second process corresponding to the out-of-process request is a process subjected to control; in the case where the second process is not a process subjected to control, shifting out the work-in-process in response to the out-of-process request; in the case where the second process is a process subjected to control, determining whether a current quantity of the work-in-process in use for the second process exceeds a control threshold in the second process; and in the case where the current quantity of the work-in-process in use for the second process exceeds a control threshold in the second process, stopping responding to the out-of-process request.