Work Loss Analysis System for High-Mix Low-Volume Production
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Solution Overview
Problem
Existing systems struggle to analyze and identify the causes of work loss in high-mix low-volume production environments, where products and components have low repeatability, making it difficult to define and evaluate work loss effectively.
Innovation Solution
A work loss analysis system that includes a calculation unit, storage unit, and input/output unit, which stores production records and threshold information to determine abnormal operation times, allowing for comparison of operation states and extraction of causes of work loss by identifying differences in worker, facility, product, and component performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If work loss analysis is performed using traditional methods for high-repeatability products, then loss cost can be calculated and prioritized, but it becomes difficult to specify causes of work loss for low-repeatability high-mix low-volume products
Solution Approach 1:
The analysis system segments work loss into distinct categories (setup time, waiting time, non-operation time) and analyzes each segment separately. This allows precise measurement of specific loss types while maintaining adaptability across different product types by applying the same segmentation framework to various production scenarios.
Solution Approach 2:
The system creates a universal analysis framework that can handle both high-repeatability and low-repeatability products through multi-functionality. The same system collects and analyzes diverse data types (operation records, worker skills, facility capabilities) regardless of product characteristics, enabling work loss specification across different product categories.
2Productivity
If production records are collected and analyzed in detail to identify work loss causes, then productivity improvement can be achieved, but system complexity and data processing requirements increase
Solution Approach 1:
The system performs preliminary data collection and organization of production records, worker skills, and facility capabilities before actual analysis. This preliminary action structures the data in advance, reducing the complexity of subsequent analysis operations and enabling efficient productivity improvement identification.
Solution Approach 2:
The analysis system acts as an intermediary between raw production data and actionable insights. It mediates by collecting diverse data from multiple sources, processing it through standardized algorithms, and presenting results in a comprehensible format, thereby reducing the complexity burden on users while maintaining detailed analysis capabilities.
Data Source
AI summary
A cause of work loss in a factory that produces high-mix low-volume products is extracted. The analysis system includes: a calculation unit; a storage unit; and an input and output unit. The storage unit stores record information related to operation time of an activity for producing a product, and threshold information for determining whether the activity of producing the product is abnormal based on the operation time. The calculation unit is configured to determine the operation time and non-operation time for each case extracted from the record information, determine abnormality for each case based on the operation time for each case and the threshold information, and output information of comparing the operation time of a case determined to be abnormal with the operation time of a case not determined to be abnormal to the input and output unit.