CN1291312A - Method and system for controlling processes - Google Patents
Method and system for controlling processes Download PDFInfo
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- CN1291312A CN1291312A CN99803098A CN99803098A CN1291312A CN 1291312 A CN1291312 A CN 1291312A CN 99803098 A CN99803098 A CN 99803098A CN 99803098 A CN99803098 A CN 99803098A CN 1291312 A CN1291312 A CN 1291312A
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Abstract
A method and computer system for controlling an industrial process are disclosed. The industrial process has problems which adversely affect its performance. A personal computer is programmed with a database and a custom application. The database contains data describing the attributes and performance of the process to be controlled. The custom application calculates the financial value of each of the problems. The calculation of the financial value of each problem can take into account market conditions which affect the amount of product which could be sold if made, the marginal profitability of the product, how much optimum process time each problem takes up and the cost and quantity of raw materials wasted due to the problem. The calculation of the financial value of each problem can take into account the impact of each problem on the process bottleneck. The financial values of the problems are used to prioritise the problems, allowing them to be remedied in accordance with their priority.
Description
Technical field
The present invention relates to control, particularly to the control of manufacture process to production run.
Background technology
A typical industrial manufacturing plant relates to the production run of many production products.Each production run is made up of many sub-production runes.A fundamental purpose of factory management is that (near optimum performance ground) makes plant operation as far as possible effectively, makes the price of product minimum.Yet it is not uncommon that a factory does not turn round best.These can be because of many different former thereby generations.One or more problems can cause many difficulties in production run or "the philosophers," referring to the philosophers or their works, outside the Confucianists's production run.For example, outage may make all production runes all stop.The obstruction of a bottle lid slideway can cause many bottles of not adding a cover in a bottled factory, thereby needs an extra operator manually to add upper cover for these bottles.In the manufacturing plant of all complexity of today, may there be the problem of thousands of operating aspects, make performance depart from best level.Because the resource that addresses these problems is not unlimited many, so which type of problem administrative authority usually solves about this and with which type of order solve these problems and face difficult choice.
Utilize existing technology, can follow the tracks of the performance of industrial processes by following method:
1. calculate the efficient (i.e. the ratio of Shi Ji output and really possible output) of production run;
2. determine the reason (even all the name of the games and duration that key link stops) of shut-down;
3. determine labour's variation (i.e. between direct labour's expense Shi Ji direct labour's expense and budget or that plan poor);
4. determine raw-material variation (i.e. between the raw materials consumption Shi Ji raw materials consumption and budget or that plan poor); With
5. determine the degree (i.e. unaccepted product quantity in making production run or when manufacture process is finished) of waste product
In these methods each all is defective.Particularly, neither one attempts to calculate the real expense financially of an independent problem in these methods of prior art, and they do not calculate the total expenses of all problems that influences industrial processes yet.So if adopt the method for all prior arts, then the administrative authority of factory can not distribute all resources with an effective and efficient manner.
The present invention is exactly these and other many defectives that will solve prior art.
Announcement of the present invention
The present invention includes and be used for a method and a system that a production run of producing product is controlled, make it can be with the performance operation of the best to this production run design, this method comprises following all steps:
Discern a problem of certain some generation in process of production, this problem is moved production run under the situation than optimum performance difference;
A key link in the identification production run, this key link have determined the maximal rate of production run operation.
Problem identificatioin on key link to the Effect on Performance of production run;
To the production run Effect on Performance, finance of computational problem are worth the problem of considering on key link;
The priority of problem identificatioin on the basis of the finance value of problem; With
Adjust all parameters of production run according to the priority of the problem of determining by the priorization step.
Preferentially, this method further comprises all steps of determining an available optimal process time and determining to have lost owing to problem how much available optimal process time.
If if can be by determining arranged if can be used for production run and can be used for producing product the process time of production run in operation production run under the optimum performance how many process times (or turnout) from operation production run under optimum performance, the available optimal process time (or turnout) that then can sell how many products derives be determined owing to a problem loss amount of one process time.So the available optimal process time is so because the loss amount of problem process time has reacted the market situation of the product of being made by production run.
In one embodiment, the present invention can determine to influence the real financial expense of all problems of production run, then can determine all different problems priority and will suitable scheduling of resource to each problem.We design a typical production run of producing a product to such an extent that move under an optimum performance.Yet production run has one or more production runes that make to be moved under the situation than optimum performance difference, thereby makes the problem of production run loss process time or turnout.
In another embodiment, method of the present invention comprise identification in the production run problem and a key link in the identification production run, this key link has determined the maximal rate of production run operation.Consider the influence of problem, a finance value of problem identificatioin to key link.Priority that then can problem identificatioin is made the decision whether correcting this problem or resources allocation can be given this problem according to the finance value of problem.
Another aspect of the inventive method is according to the profit of product problem to be assessed, and has reacted market situation and the priority that allows to utilize the market situation problem identificatioin like this.Select as another, can by according to labour's expense to because the finance value of estimating problem identificatioin process time of problem production run loss.
Another aspect of the inventive method is to determine because how many process times are the problem production run lose.The step of the finance value of computational problem can comprise according to losing the step of how many process times problem being assessed owing to the problem production run.
Production run can be produced restriction or sold restriction.When how many products were production run can produce just can sell how many products in market, this production run was produced restriction.When all over products that can produce is not can both sell in market the time, this production run is sold restriction.Another aspect of the present invention is the finance value for problem identificatioin, determine production run whether be produced restriction whether sold restriction with definite production run.Another aspect of the present invention be by according to product profit to because how many process times are the problem production run lose and assess, determine that production run produced the degree of restriction and the degree that production run is sold restriction.Another aspect of the present invention is when to can not assess the degree of process time of any loss according to profit the time, according to labour's expense to assessing the process time of loss.
Another aspect of the inventive method is to determine owing to make key link problem production run out of service lose how many process times, owing to make key link move to such an extent that lose how many process times and because how many process times are the problem production run that makes product become waste product lose than the slow problem production run of expectation in key link or after key link.
The present invention also comprises a computer system that is used to implement the inventive method.Computer system of the present invention can comprise and be used to import the simulated data relevant with production run, thus set up production run a computer model device and be used to import the device of the performance data that obtains by the performance that monitors production run.In one embodiment, be provided for discerning the device of a key link in process of production, this key link has limited the maximal rate of production run operation.System also can comprise the device of a finance value of all problems that are used for definite production run, system also comprises and being used for by considering that all problems are determined the influence of key link because a problem or a plurality of problems one, the production run loss process time amount device.
If another aspect of the present invention is to be used for production run to move under optimum performance, if then in the available time, produce the device how many products product can sell.Determine process time of available the best in assessment, to reflect market situation like this with the product volume that can sell to problem.
Another aspect of the present invention be used for according to the profit of product to since problem can with the device assessed of optimal process leeway and be used for according to labour's expense to since problem can with the device assessed of optimal process leeway.
Further aspects more of the present invention relate to be used for determining production run be produced restriction and sold the device of the degree of restriction; With in production run be produced when restriction according to the profit of producing and production run be when being sold restriction according to labour's expense to because the device of assessing the process time of problem production run loss.
Another aspect of computer system is the device that is used for assessing according to product profit all problems, has reflected that like this market situation and permission are used for market situation to determine the priority of all problems.
Another aspect of computer system is to be used for determining a device owing to the slow working time of problem, represents this slow working time owing to make key link lose how many process times with a problem production run than the slow-footed speed operation of expectation; Determine a device with being used for, represent this shut down time owing to make key link problem production run out of service lose how many process times owing to the shut down time of problem; Determine a device owing to the time of key to the issue link waste with being used for, the time representation of this waste is because how many process times are the problem production run that makes product become waste product in key link or after key link lose.It is in order according to the loss amount of the process time that causes owing to problem problem to be assessed that these devices are provided.
Preferentially, this method further comprises to be determined because the step of how many extra personnel operation production runes of problem needs, the step of wherein determining all finance values comprises to be determined because the finance value of how many extra personnel operation production runes of problem needs and step that how many profits problem identificatioin reduces also are according to owing to how much extra the finance value of problem needs personnel operation production run carry out.
Preferentially, this method also further comprises determining because the problem production run need with how many raw-material all steps, the step of wherein determining all finance values comprise determine since the step how many profits are the problem production run need reduce with how many raw-material all finance values and problem identificatioin also according to owing to how many raw-material all financial values are the problem production run need carry out with.
From we will be well understood to these and other aspect of the present invention to the simple description of appended all figure and claims.
The simple description of all figure
Fig. 1 is the block scheme that an expression applies the present invention to simple potato processing and package plant;
Fig. 2 is the process flow diagram of all basic steps that the present invention relates to of an expression;
Fig. 3 is a snapshot for the main computer screen of computer program of the present invention;
Fig. 4 is a snapshot that is used to import order of classes or grades at school data computing machine screen with the production run of the present invention's control in order to simulate;
Fig. 5 is used to import production run, variant, a snapshot of sub-production run and starting material data computing machine navigation menu bar for the production run of simulating with the present invention's control;
Fig. 6 is used to import a snapshot of the computer screen of production process data in order to simulate production run with the present invention control;
Fig. 7 is used to import a snapshot of the computer screen of variant data in order to simulate production run with the present invention control;
Fig. 8 is used to import a snapshot of the computer screen of sub-production process data in order to simulate production run with the present invention control;
Fig. 9 is a snapshot that is used to import starting material data computing machine screen with the production run of the present invention's control in order to simulate;
Figure 10 is used to import a snapshot of the computer screen of all reason groups in order to simulate production run with the present invention control;
Figure 11 is a snapshot that is used for all reason groups are added to the computer screen on all variants;
Figure 12 is a snapshot that is used for all reason groups are added to the computer screen on "the philosophers," referring to the philosophers or their works, outside the Confucianists's production run;
Figure 13 is a snapshot that is used to import the computer screen of all sets of numbers;
Figure 14 is a snapshot that is used for all reason groups are added to the computer screen on all sets of numbers;
Figure 15 is used to select production run, order of classes or grades at school, and data and variant also are used to import a snapshot of the computer screen of production data;
Figure 16 is a snapshot that is used to import data computing machine screen shut down time;
Figure 17 is a snapshot that is used to import the computer screen of yield data;
Figure 18 is a snapshot that is used to import the computer screen of waste product data;
Figure 19 is the process flow diagram of all basic step of an expression when according to all problem values all problems being assessed and a production run being controlled;
Figure 20 is a process flow diagram that calculates the available storage list of being produced restriction in being illustrated in during the underlying table;
Figure 21 is one and calculates in being illustrated in during the underlying table because the process flow diagram of the value of the labour's time that loses that problem causes;
Figure 22 is the process flow diagram of an expression loss cost of products Evaluation Method;
Figure 23 be one calculate a problem in being illustrated in during the underlying table shut down time part the process flow diagram of value;
Figure 24 be one calculate a problem in being illustrated in during the underlying table slow working time part the process flow diagram of value;
Figure 25 is the process flow diagram of the value of a key link waste part of calculating a problem in being illustrated in during the underlying table;
Figure 26 is the process flow diagram of the value of a waste of raw materials part of calculating a problem in being illustrated in during the underlying table;
Figure 27 is one and all parts of the value of a problem added up in being illustrated in during the underlying table, with this value extrapolation with according to its process flow diagram of priority of value problem identificatioin.
Be the detailed description that the present invention invents below.For the purpose of understanding easily when describing aspects of the present invention, we are with reference to an example that is used to pack simple industrial processes of potato.We do not want to allow this description and example that the scope of being determined by claims of the present invention is applied restriction.
Typical factory relate to every day several order of classes or grades at school and several produce the production run of " all variants " from all starting material.Each production run can have all subprocess.One " variant " is a product or the closely similar all products of its all feature.
In the example that the potato of explained in general is processed and packed in Fig. 1, factory 1 receives all starting material 2 and will be with all production runes (or all production lines) 3,4 and 5 process them, all production runes 3,4 and 5 produce all variants 6,7,8 and 9-1,2 and 3 pounds potato can and produce all variants 10 and 11-is all with potato chips bag salt and light.Each variant all has many different features.These features comprise the personnel amount of the best that is used to operate production run, the key link speed of the maximum of production run, the selling price of variant, the title of the break-even manufacturing expense of the unit of variant and all different problem set.Many different problems may appear in a production run." all problem set " is to make all features of production run depart from all dissimilar all problems of their value all the bests or expectation.For example, production run may be moved too slowly (all " operation slowly " problem), possibly a production run is distributed too much personnel (all " too much personnel " problem), production run may quit work (all " shut down time " problem), has wasted process time (all " key link waste product " problem) and may waste all starting material (all " waste of raw materials problem ") thereby may produce waste product in key link or after key link.
The present invention includes a personal computer 12, this computing machine is programmed simulates industrial processes or factory 1, and implements some calculating with the application program 13 of customization.In case implemented all calculating, printer 14 prints a problem priority table and this table is used for definite priority ranking that all parameters of factory 1 are adjusted.
The application program 13 of customization comprises the program coding that writes out especially, this code and 15 interactions of a commercially availabie database, and this database 15 is preferential is the Access_ that can buy from Microsoft (Microsoft).The application program 13 and the database 15 of customization preferentially move in the environment of a Windows_95 (Win95), but concrete operating system and database is not conclusive for purposes of the invention.We will describe the interaction of the application program of customization and it and database in detail now, and we understand and write out to realizing that computer code required for the present invention is in common those skilled in the art scope in power.
The most basic all step of the inventive method as shown in Figure 2.At first, in step S1 simulation production run or factory.Secondly, in step S2 collection production process data and with they input databases.Calculate all finance values and produce a problem priority table for all problems at step S3 according to all finance values.Adjust all parameters of production run according to the problem priority table at step S4.We will describe in these steps each in detail now.
1. simulate factory or production run
In order to simulate factory or production run, pass through the main menu screen 20 of the application program 13 of customization as shown in Figure 3 and import data to computing machine.Click the mouse or the indicating device of computing machine 12 on the task icons 24 of user in menu bar 22, menu 26 of drag down is also clicked on simulation factory icon 28.This makes him or she enter as shown in Figure 4 factory's simulated screen 30.As shown in Figure 4, factory's simulated screen is made up of the graphic representation by 10 index cards, and graphic table is shown with a common configuration that is used for the application program of all Win95s.Each index card comprises all drop-down lists that are used to import all territories of data or comprise the data of having imported.Set up the model of production run or factory with them.
All index cards are as follows: order of classes or grades at school card 32, and production run card 34, variant card 36, starting material card 38, sub-production run card 40, reason group card 42, sets of numbers card 44, object card 46, card 48 and customization variable card 50 are measured in customization.We will describe all cards 32 to 44 in detail.The present invention need not block 46,48 and 50.
Show production run card 34, variant card 36, starting material card 38, each screen of sub-production run card 40 all has many records.The user can navigate by all records by enough navigation menu bars 51 as shown in Figure 5.The navigation menu bar has following all buttons: MoveNext (moving down arrow) 53, it jumps to next record, MovePrevious (on move arrow) 52, it jumps back to a record, MoveFirst (moving on to first arrow) 55, it jumps to first record and MoveLast (moving on to last arrow) 56, and it jumps to last record.To write down numeral is presented in the territory 54.All new records are added to last record go up and press MoveNext by moving.This provides the record of a blank.When record was filed or edits, the user pressed MoveNext and preserves information.
A. order of classes or grades at school card:
Order of classes or grades at school card 32 comprises three territories 321,322 and 323, and they define all order of classes or grades at school of working in the factory.In the example that potato is as shown in Figure 4 processed and packed, three order of classes or grades at school are arranged: day shift, afternoon shift and night shift.The user clicks on next index card then as long as the title of all order of classes or grades at school is imported all order of classes or grades at school territory.
B. production run card:
In the example of potato processing and packing, three production runes are arranged, production line K1 is used for potato put into 1 pound can, and production line K2 is used for putting in 1,2 and 3 pound the can potato and the section production line, and its is produced with salt and light potato chips.In the example of potato processing and packing, be that to be stored in the data of all different record input in the database 15 as shown in the table by the production run card:
| Production line: | K1 | K2 | The section production line |
| The production run title | K1 | K2 | The section production line |
| Total labour productivity | 20 | 20 | 22 |
| Target group | N／A | N／A | N／A |
| The key link production run | Be | Be | Be |
Table 1: all records of production run
C. all variant cards
As mentioned above, one " variant " is a product or the closely similar all products of its feature.In order to simulate factory's each variant of essential definition.In our example, all variants are 1,2 and 3 pound potato can and all potato chips bags.As shown in Figure 7, import all features of all variants of production runes at variant card 36.With a specific territory in each feature input variant card 36.All different territories and all drop-down lists are:
The production run title, for example, for the K1-drop-down list 361 of 1 pound of jar of potato.
The variant title, for example, 1 pound of can-drop-down list 362.
Situation-the territory 363 of all production units---for example all 1 pound of cans.
Maximum key link the speed (" MBS of variant " v "
v")-territory 363-this be the maximal rate (i.e. the maximal rate of the slowest sub-production run) that a production run can be moved, measure with production unit hourly.Each production run all has the sub-production run of a key link, the maximal rate that its decision production run can be moved.In each situation, all must identify this maximal rate.
Be used to produce personal best's quantity (" OCS of variant v
v")-for optimal number-territory 365 of the required operating personnel of the production run of moving a specific production variant v.
For break-even the manufacturing expense (" UMC of the unit of variant " v "
v")-produce the expense of an extra production unit of variant, comprise all starting material, all wrappage, extra energy cost, the expense of extra migration refuse and extra dispensing expense-territory 366.
The selling price (" USP of unit of variant v
v")-selling price-territory 367 of each production unit.
Extra the capacity (" PC% that is produced restriction of variant v
v")-additional capacity of the variant that can sell exceeds the number percent-territory 365 of current production level.
Capital consumption-territory 369-in the present invention need not.
ABS conversion title-drop-down list 370-in the present invention need not.
Output conversion title-drop-down list 371-in the present invention need not.
All reason groups-for all possible reason-Zhu drop-down list 372,373 and 374 of all problems of production run.We will be described below their detailed situation.
Reason group of not hitting the target and target group-Zhu drop-down list 375 and 376-in the present invention need not.
In the example of potato processing and packing, for the data of each variant as shown in the following table:
| The production run title | ????K1 | ????K2 | ???K2 | ???K2 | The section production line | The section production line |
| The | 1 pound of | 1 pound of | 2 pounds of cans | 3 pounds of cans | Light | With salt |
| Production unit | Case | Case | Case | Case | Pound | Pound |
| ?MBS： | ????1000 | ????1000 | ???600 | ???400 | ????3000 | ????2000 |
| ?OCS： | ????25 | ????28 | ???28 | ???28 | ????15 | ????17 |
| ?UMC： | ????2 | ????2 | ???5 | ???7 | ????0．55 | ????0．6 |
| ?UPS： | ????5 | ????5 | ???9 | ???12 | ????2 | ????2 |
| ?PC％ | ????10 | ????10 | ???0 | ???2 | ????20 | ????20 |
Table 2: all variant records
D. "the philosophers," referring to the philosophers or their works, outside the Confucianists's production run card:
Each production run can be resolved into "the philosophers," referring to the philosophers or their works, outside the Confucianists's production run.Sub-production run is a logic step or the equipment with in process of production, and this equipment is a machine typically, for example, be used for potato pack into can filler or be used for to the add salt tank of potato chips with salt.Though in a production run, have many different sub-production runes, have only those relevant sub-production runes to be identified and to be included in the plant model.All relevant sub-production runes comprise:
The sub-production run of speed critical link: this is the sub-production run that minimum maximal rate is arranged, so be the sub-rate process of maximum speed limit.Must this sub-production run of simulation.
Output key link subprocess: this is the sub-production run of limit production process yield in the most of the time.It can be identical with the sub-production run of speed critical link.The sub-production run of output key link is the sub-production run that maximum key link speed and the minimum product of number percent rise time are arranged.Simulating this process chooses wantonly.
The subprocess of all nearly key links: these are approaching or usually are all subprocess of output key link.Simulating this process chooses wantonly.
Getting back to the potato packaging process, is can filler for the speed critical link subprocess of 1 pound of can production run K1.It also is the key link of output.For 2 pounds of can production run K2 situations is identical.In the section production line, the key link of speed is a deep fryer for light potato chips, is to add salt tank for the potato chips with salt.For simplicity, in this example, we do not have all other subprocess at supposition.
Simulate each production run and be included in the relevant sub-production process information of input in the sub-production run card 40, as shown in Figure 8.The user selects production runes (production line of for example cutting into slices) with drop-down list 401, and selects the variant potato chips of salt (for example with) of production runes manufacturings with drop-down territory 402.The sub-production run of drop-down list 403 input (for example add salt tank-be speed critical link subprocess in this situation) maybe can be from a sub-process name inventory chooser process.Show that in drop-down list 404 shut down time, the reason group name claimed, drop-down list 404 comprises a reason group inventory (as the input the described all reasons for shut down time in specific subprocess) in the content relevant with Figure 10.The percentage of 405 input key links in the territory.This is the turnout percentage by specific key link subprocess.For example, if two parallel can fillers form a key link, then each loader all will be the part of key link.In example shown in Figure 8, add the turnout that the salt tank subprocess is represented 100% key link.
Be used for for all subprocess K1, the data of the speed critical link subprocess of each are as shown in the table in K2 and all slicing processes:
| The production run title: | K1 | K2 | K2 | K2 | The section production line | The section production line |
| The variant title: | 1 pound of | 1 pound of | 2 pounds of cans | 3 pounds of cans | Light | With salt |
| Sub-production run title: | The K1 can filler | The K2 can filler | The K2 can filler | The K2 can filler | Deep fryer | Add salt tank |
| The % of key link: | 100 | 100 | 100 | 100 | 100 | 100 |
Table 3. "the philosophers," referring to the philosophers or their works, outside the Confucianists process record
E. starting material card:
As shown in Figure 9 starting material card 38 will be relevant with all raw-material values the data input model.For each variant, have starting material at least.Define starting material with following item:
Production run title-drop-down list 381-comprises the title (seeing also Fig. 6) of all production runes.
Variant title-drop-down list 382-comprises the title (seeing also Fig. 7) of the variant of all definition.
Starting material title-drop-down list 383, allow from before the starting material title of definition directly import or select.
Raw-material unit-drop-down list 384-comprises the title (seeing also Figure 13) of all reason sets of numbers.
Raw-material per unit expense (RW$
r)-territory 385.
This is that supposition does not have the refuse loss for minimum starting material capacity-territory 386-, in order to produce the required raw-material minimum number of a production unit of variant.
Target group-drop-down list 388-and conversion title-drop-down list 389-and the present invention are irrelevant.
For being used for all subprocess K1, the raw-material data of K2 and all section production lines are as shown in the table:
| The production run title | The variant title | The starting material title | Starting material unit | The prices of raw and semifnished materials | Minimum starting material capacity |
| ????K1 | 1 pound of can | Potato | Pound | ???0．1 | ????10 |
| ????K1 | 1 pound of can | Can | Can | ???0．05 | ????10 |
| ????K2 | 1 pound of can | Potato | Pound | ???0．1 | ????10 |
| ????K2 | 1 pound of can | Can | Can | ???0．05 | ????10 |
| ????K2 | 2 pounds of cans | Potato | Pound | ???0．1 | ????20 |
| ????K2 | 2 pounds of cans | Can | Can | ???0．1 | ????10 |
| ????K2 | 3 pounds of cans | Potato | Pound | ???0．1 | ????30 |
| ????K2 | 3 pounds of cans | Can | Can | ???0．15 | ????10 |
| The section production line | Light | Potato | Pound | ???0．1 | ????3 |
| The section production line | Light | Bag | Bag | ???0．02 | ????1 |
| The section production line | With salt | Potato | Pound | ???0．1 | ????3 |
| The section production line | With salt | Bag | Bag | ???0．02 | ????1 |
Table 4: all starting material records
F. all reason group cards:
One " reason group " be for all different problems in factory or production run (all overstaffed problems, all shut down times problem, all slow operation problems, all key link waste product problems and all waste of raw materials problems) one group of reason.By defining all reason groups at as shown in figure 10 reason group index card 42 input informations.Each reason group all has a title as shown in drop-down tabulation 421.With reason group input drop-down list 421.Each reason group all is made up of one or more reasons for a particular problem.In described example, K1/K2 organizes and comprise all conversions shut down time, and can is blocked at the decrater place, in the obstruction of sending into the can filler place etc., as shown in the table of table 422 input.Import these, a reason definition of every production line.All row 423 are all features of each reason.When clicking on the specific reason group of operator in drop-down menu 421, appear at reason table and all characteristics of correspondence row in that reason group.Can import relevant characteristic then.All characteristics of described reason group are:
This is a number that is illustrated in the grade of a specific reason in the reason group for reason-code-Lie 424-.
This is an illustrative title for a reason in the reason group for reason title-Lie 425-, and for example, reason group as shown in figure 10 comprises a reason title " conversion ".This is illustrated in the problem that all conversions between all variants cause.
Key link waste product sign-Lie 426-this be an expression except the reason of presumable any other type, specific reason is as a sign of key link waste product reason in the reason group.
Spoiled goods report position (" WRU
Pv")-Lie 427-these are all waste product units, concrete reason will be with these units, for example, the kilogram of immature soil beans, jar, or case is reported out.
(" WRU is to PU to production unit in the spoiled goods report position
Pv")-Lie 428-this be the digital conversion factor that all spoiled goods reports position is transformed into all production units.
Attention can not be used for the present invention at following all territories and all signs shown in the index card 42: set up sign, subclass title, DT class formative, basic DT classification, waste product clauses and subclauses transcode, DT target, SR target, XC target and BW target.
Be used for illustrating that the simulated example of factory has defined four reason groups.The reason group card of data import to(for) potato processing and package plant are listed in the K1/K2 waste product respectively, and K1/K2 moves slowly, and K1/K2 shut down time and the overstaffed table 6 of K1/K2 are in 7,8 and 9.
| Reason-code | The reason title | Key link waste product sign | The spoiled goods report position | The spoiled goods report position is to production unit |
| ????1 | Conversion | Very | The can of filling | (0.1 being 10 cans of every case) |
| ????2 | Can drops from travelling belt | Very | The can of filling | ????0．1 |
| ????3 | Sending into the obstruction of can filler place | False | Can | |
| ????4 | Can is blocked at the decrater place | False | Can | |
| ????5 | Leak | Very | The can of filling | ????0．1 |
Table 6:K1/K2 waste product reason group
| Reason-code | The reason title | Key link waste product sign | The spoiled goods report position | The spoiled goods report position is to |
| 1 | Do not fill | False | ||
| 2 | In the underproof sealing of the head of filling | False | ||
| 3 | Leak | False | ||
| 4 | The operator selects | False | ||
| 5 | The setting of mistake after conversion | False |
Watch 7:K1/K2 moves the reason group slowly
| Reason-code | The reason title | Key link waste product sign | The spoiled goods report position | The spoiled goods report position is to | |
| 1 | | False | |||
| 2 | Can is blocked at the decrater place | False | |||
| 3 | Sending into the obstruction of can filler place | False | |||
| 4 | The can that leaks | False | |||
| 5 | Spilling of can filler delivery outlet | False | |||
| 6 | Underproof sealing on can filler | False |
Table 8:K1/K2 reason shut down time group
| Reason-code | The reason title | Key link waste product sign | The spoiled goods report position | The spoiled goods report position is to | |
| 1 | Do not add | False | |||
| 2 | Leak | False | |||
| 3 | Be scheduled to too many grass hand | False | |||
| 4 | The product conversion that is forced to | False |
The overstaffed reason group of table 9:K1/K2
G. all connection reason groups:
After the data of all different reason groups of input definition, all reason groups can be added on all variants and the "the philosophers," referring to the philosophers or their works, outside the Confucianists's production run.We remember when describing variant index card 36 (seeing also Fig. 7), all reason groups territory are not discussed.All reason groups territory among Fig. 7 (be overstaffed 372, move 373 slowly, key link waste product 374 and waste of raw materials 376) is all drop-down menus, and they allow the user to select a known reason group in the input of reason group card.In Figure 11, illustrated all reason groups have been added on all variants.For all subprocess similar all reason groups are arranged, they are added on all subprocess with like all subprocess screen classes as shown in figure 12.
H. all sets of numbers:
Typically with the production unit of finishing or part is finished (for example all potato cans or adorn the chest of all cans) report waste product.So need provide one at spoiled goods report position (" WRU
Pv") and the waste starting material (" WasteQtyp
Vsd") between conversion factor (" WRUtoRUp
Vsd").The definition of all reason sets of numbers provides this conversion factor.
Must be used for reason sets of numbers of definition between the reason group of all waste of raw materials problems and each starting material at each.In the situation of potato processing and package plant, producing variant for each all has two starting material.Unless data are identical, all need a reason sets of numbers for each starting material of each variant.
The user clicks on sets of numbers index card 44.Referring now to Figure 13.Drop-down list 441 comprises the title (seeing also Figure 10) of all reason groups that defined.The title of 442 input sets of numbers in the territory.Table 443 is made up of each reason in the reason group of regulation in territory 441.The definition (row 427) of setting up among the next comfortable Figure 10 in spoiled goods report position (row 444).Unique input data are WRUtoRUp
Vsd, be input to row 445.
K1 and K2 production line for described potato processing and package plant need four waste product reason sets of numbers.For all cans is two (that is, one for 2 pounds of cans and one for 3 pounds of cans) and be two for potato.These are as table 10, shown in 11 and 12.
| Reason-code | The reason title | The spoiled goods report position | The spoiled goods report position is to starting |
| 1 | Conversion | The can of filling | 1 |
| 2 | Can drops from travelling belt | The can of filling | 1 |
| 3 | Sending into the obstruction of can filler place | Can | 1 |
| 4 | Can is blocked at the decrater place | Can | 1 |
| 5 | Leak | The can of filling | 1 |
Table 10:K1/K2 can reason sets of numbers
| Reason-code | The reason title | The spoiled goods report position | The spoiled goods report position is to starting |
| 1 | Conversion | The can of filling | 2 |
| 2 | Can drops from travelling belt | The can of filling | 2 |
| 3 | Sending into the obstruction of can filler place | Can | 2 |
| 4 | Can is blocked at the decrater place | Can | 2 |
| 5 | Leak | The can of filling | 2 |
2 pounds of potato reasons of table 11:K1/K2 sets of numbers
| Reason-code | The reason title | The spoiled goods report position | The spoiled goods report position is to starting |
| 1 | Conversion | The can of filling | 3 |
| 2 | Can drops from travelling belt | The can of filling | 3 |
| 3 | Sending into the obstruction of can filler place | Can | 3 |
| 4 | Can is blocked at the decrater place | Can | 3 |
| 5 | Leak | The can of filling | 3 |
Table 12:K1/K2 can reason sets of numbers
I. all reason sets of numbers are added to plant model:
With reference to Figure 14.The all reason sets of numbers imported on the sets of numbers screen that to just describe with starting material card 38 are added on the plant model.Select waste product reason sets of numbers with drop-down list 387.And it is added on the plant model with the navigation menu bar.
2. the input of production process data
After having set up a model of production run or factory, next step is the input data relevant with the actual performance of production run or factory.For each production run, the staff of factory will be for each variant input data.Four class data are arranged: (1) production data; (2) shut down time data; (3) yield data and (4) waste product data.
On main screen 20, click indicator device, the task of leaving behind menu 26 on the Task (task) 24 of operator in menu bar 22.Referring to Fig. 3.He clicks on production data input icon 25 then.This sets up data entry screen curtain 60 as shown in figure 15.The operator selects order of classes or grades at school (for example afternoon shift) in drop-down list 601 then, imports data (for example 1/1) in territory 602, selects production run (for example K1 production line) and select variant (for example 1 pound of can) in drop-down list 603 in drop-down list 604.For four class data (1) production datas; (2) shut down time data; (3) each class in yield data and (4) waste product data has the index card 610,620,630 and 640 of a correspondence respectively.
Click (seeing also Figure 15) allows the operator to import production data on the index card 610 producing.In every kind of situation, the operator will be in the territory 611 inputs for actual the hourage (" APH of relevant order of classes or grades at school by personnel's group performance production run
Vsd") (for example 8 hours).The speed (" ABS of the key link of the reality of the speed of 612 input production runes in the territory-represent with units per hour
Vsd") (for example 800), 613 inputs are with the output (" O of unit representation in the territory
Vsd") (for example 5,00), actual operating personnel's quantity (" ACS of 614 inputs in the territory
Vsd") (for example 25).Then, the operator selects an overstaffed reason and a reason of moving slowly with drop-down list 615 and 616.See also Fig. 7, territory 372 and 373.
With reference to Figure 16, the operator clicks index card 620 shut down time, input and data relevant with shutdown times shut down time in the specific production run process of a variant.For same order of classes or grades at school, on the date, production run and the variant of just having selected can be imported many shut down times of clauses and subclauses.Shut down time, index card 620 comprised the table 621 that is used for that purpose.Table 621 has a sub-production run drop-down list 622, and it allows for process of selecting and variant, from sub-production run of sub-production run group selection of definition sub-production run screen 40 (seeing also Fig. 8).Making the suitable reason group for sub-production run then is available for all shut-down reason groups.Then, the user selects a reason-code (in reason group screen curtain 42 inputs) (seeing also Figure 10) from drop-down list 623, and it is added on the specific sub-production run in sub-production run screen 40 (seeing also Figure 12).After having selected a sub-production run and reason-code, the operator can import (" DT shut down time respectively in territory 624 and 625 now
Pvsd") shutdown times.For the variant of selecting on the order of classes or grades at school of selecting to repeating this operation all shut down times of on all sub-production runes, having taken place.
Figure 17 represents output index card 630.Click the starting material quantity that this card allows to import the production run that is used to select.For identical order of classes or grades at school, on the date, production run and the variant of just having selected can be by clicking the starting material that drop-down list 632 in table 630 selects for a specific variants one to define (" starting material title).This inventory comprises all starting material of the variant that is used to select.In the starting material screen, defined this inventory (seeing also Fig. 9).Each raw-material quantity (" RL that will be used for the production run of the variant on the order of classes or grades at school of selecting, selected
Vsd") input row 632.
Figure 18 represents waste product data index card 640.Clicking this card allows input to be used for the data of waste of raw materials and key link waste product.For identical order of classes or grades at school, the date, production run and the variant of just having selected, the drop-down list 641 of the code (seeing also Figure 10) that all that can list former input by click have defined is selected waste product reason groups (seeing also Fig. 7, territory 374).In case selected reason-code, automatically loaded the description of waste product reason.Referring to row 642.Raw-material quantity (" WasteQty with waste
Pvsd") import row 643 and the waste product frequency is imported row 644.All starting material and the waste product problem that takes place when producing variant on specific date and order of classes or grades at school repeated this operation.
3. all problems in a production run are set up the priority list of problem
We have simulated factory or production run and have imported relevant performance data now.The operator clicks the printed report icon 27 (seeing also Fig. 3) in main screen 20 now.This operation begins the priority list of computational problem and it is printed.
Be the detailed description of calculating of the priority list of problem below.With reference to Figure 19, in the evolution of the priority list of problem, 10 basic steps are arranged, that is:
1. set up " the available saving of being produced restriction is shown ".Step S10.
2. be evaluated at during the underlying table too much personnel's part (XCLL$ of a problem p among the BTP
Pn).Step S12.5 week typically during the underlying table.
3. be evaluated at the production run part shut down time (DT$ of a problem p among the BTP
Pn).Step S14.
4. be evaluated at production run slow working time of the part (SR$ of a problem p among the BTP
Pn).Step S16.
5. be evaluated among the BTP because the (BW$ loss of time of key link waste product (unaccepted product in the sub-production run of key link or after the sub-production run of key link) the part producing process of a problem p
Pn).Step S18.
6. be evaluated at the waste starting material part (RW$ of a problem p among the BTP
Pn).Step S20.
7. will in BTP, the total value of problem p add up.Step S22.
With extrapolation method ask one 1 year the time interim problem p expense.Step S24.
9. for all problems repeating step 1 to 8 that in BTP, takes place in process of production.Step S26 and S28.
10. with total value all problems is stored so that the report of the priority that has problems is printed report and adjusted production run according to the value of all problems.Step S30.
11. we will be described in detail in these steps each now.
1. set up " the available saving of being produced restriction is shown ".
If production run does not have the efficient work with 100%, then, will allow to make all extra unit of variant in order to make production run reach 100% efficient.If these units can be sold away (that is, production run is " being produced restriction "), then will cause extra profit.If these units can not be sold away (that is, production run is " being sold restriction "), the efficient of then improving process will cause producing with the less time unit of equal number, so just reduced labour cost.
The available saving table of being produced restriction is with 100% effective all chronomeres of work, and promptly the number of minutes that carries out work in production run (" BTP ") during the underlying table in as expecting is analyzed process.It preferentially during the underlying table 5 week.In case done like this,, can also waste what such units with problem each problem is assessed except how many starting material are problem wasted and working time.
When first step, we calculate in BTP the 100% quantity PCM of all units that effectively works (or " optimal process time ") that can use for process
nInstant value PCM$ with these units
nThe available saving table of being produced restriction that is stored in the database 15 is discerned each variant that can sell out overhead provision in BTP (being each variant of being produced restriction), the quantity PCins of the optimal process time that needs for the amount of production exterior capacity
VnAnd the value PCMins$ of the per minute of that process time
VnTo use these values in all steps afterwards, so as expense evaluation problem and production loss, the relevant part of loss profit that can produce from the sale of all extra units.
With reference to Figure 20.Following calculating PCU
Vn, the quantity of the overhead provision of a variant v that can in BTP, sell.Obtain the output O of variant v among BTP from database 15
VnIf number percent PC% with their manufactured all unit that come out just may sell
v-be represented as a number percent of current production.By with PC%
vMultiply by O
VnFind PCU
VnStep S40.
Below, by with PCU
VnMultiply by the boundary profit UMP of unit of variant v
vAll extra unit value (gross profit) PCU$ of the variant v that calculating can be sold
VnStep S42.Unit boundary profit UMP in step S44 calculating
vBe the selling price USP of unit that all is stored in a variant in the database 15
vWith the break-even manufacturing cost UMC of unit
vBetween poor.
Then, by selling the quantity PCU of all extra variants
VnDivided by maximum key link speed MBS for specific variant
v(being stored in the database 15) is calculated as and produces the optimum process time PCMins that all extra variants need
VnStep S46.
At last, calculate each optimal process time (minute) value PCMins$
VnIf it is used to produce the extra sale capacity of variant v.By value PCU$ with all extra units of variant v
VnDivided by the optimal process time PCMins that needs for those extra variants of production
VnAccomplish this point.Step S48.
Repeat these steps and set up the available saving of being produced restriction and show for all variants of producing in during underlying table.Step S50.Shown in step S50 with one reduce each optimal process time (minute) value PCMins$
VnOrder all variants are arranged in the table.This table has four row, i.e. variant identification v, for optimal process time of variant v (minute) value PCMins$
VnWith the optimal process time that can be used for producing variant v (minute) quantity PCMins
VnThe 4th row, all excess times (minute), be empty in this stage, but will use it later on.
2. the overstaffed part of a problem p in being evaluated at during the underlying table:
With reference to Figure 21.An important step when the overstaffed part of a problem of assessment is to determine during underlying table for variant v because the labor hours XCLL that overstaffed problem p is total
PvnBy at first determining in a production run because the working time of overstaffed loss (hour) XCLL
Pvsd, during underlying table, it is added up then and accomplishes this point.By finding the personal best to count OCS
vCount ACS with actual person
VsdBetween difference and it be multiply by in production run actual process time of APH to all variant v operations
VsdDetermine XCLL
PvsdStep S52.When process is simulated with OCS
vBe stored in the database 15 and when production run finishes, obtain actual person and count ACS
VsdActual process time of APH with operation
VsdAnd with they input databases.Determining in the production run because the total labor hours XCLL that overstaffed problem causes
PvsdAfter, by the XCLL in all order of classes or grades at school in will be during underlying table and the fate
PvsdAdd up and find during underlying table for a variant because problem p causes XCLL in total too much working time
PvnStep S54.Then by will be in process of production for the XCLL of all variants
PvnAdd up and find labor hours XCLL for total loss of whole process of production
PnStep S56.
By with XCLL
PnMultiply by total labour productivity AULR for process (being stored in the database 15 when the dummy run phase in advance) assessment because the XCLL$ in working time of the loss that overstaffed problem causes
PnStep S58.
3. assess shut down time, slowly operation and key link waste product problem:
A typical production run has three source-shut down times (promptly when production run stops fully) of losing process time, slowly operation (promptly when production run is moved with the speed lower than iptimum speed) and key link waste product are (when produce product in the speed critical link, but in the time of must be scrapped, so just wasted process time).
That the mode of assessment of loss process time and production run are produced restriction or sold restriction relevant.A production run is produced restriction when company can sell the more products that can produce than it.A production run is sold restriction when company can not sell any product of Duoing that can produce than it.If production run is produced restriction, then can utilize go to make extra product the process time of some or all loss, if production run has been operated on its optimum level.So, the process time of the boundary profit assessment of loss of the enough additional product of energy.Suppose that production run just is being operated on its optimum level, can accomplish this point by the value of determining a chronomere.If process is sold restriction, then can be enough from process time of the saving assessment of loss that improves the labour cost that production run efficient obtains.
In any case, with a process time that is called the method assessment of loss of " loss cost of products Evaluation Method ", this method is also referred to as " Evaluation Method of being produced restriction " at first, and it is the module of an application program 13.Loss cost of products Evaluation Method with the boundary profit assess loss as much as possible process time (minute) and export the value of the process time of losing.
A. lose the cost of products Evaluation Method:
Implement data in the saving table of being produced restriction that the program module of loss cost of products Evaluation Method will describe and one in the above because the optimal process time of problem p loss (minute) amount OPM
PnAs input.All output of program module be the loss of input process time (minute) all or part of maximal value OPM$
PnAnd when algorithm finishes also the process time of not evaluated loss (minute) amount OPMR
Pn
With reference to Figure 22, all basic steps in loss cost of products Evaluation Method are:
1. with the row PCMins of the available saving table of being produced restriction
VnThe new row that are called RemMins (promptly remaining all minute) of all content replications in.Step S60.
To the loss the optimal process time (minute) value carry out initialization, it is equalled zero (is OPM$
Pn=0).Step S62.
3. determine the position of variant in the available saving table of being produced restriction, the time of being produced restriction of this variant (minute) value PCMins$
VnMaximum and its RemMins value are greater than zero.Step S64.If there is not such variant, then finish assessment (being that variant is sold restriction).Program output OPMR
Pn, otherwise program is proceeded.Step S66.
4. for the variant of in step S64, selecting, determine the evaluated optimal process time (minute) amount OPM
PnWith among the RemMins less one.Because these times (minute) produced restriction, so this is called as " available optimal process time (minute) " UOPM
Pn-can produce the more variant that can sell with them.Step S68.
With the available optimal process time (minute) UOPM
PnMultiply by minute value PCMmins$ that is produced restriction, and product is added to the optimal process time (minute) value OPM$
PnOn.Step S70.
From the input loss the optimal process time (minute) OPM
PnWith two values in all RemMins row derive the available optimal process time (minute) UOPM
PnStep S72.
If the optimal process time (minute) OPM
PnWith the RemMins both greater than zero, then get back to step S64.Step S74 and S76.Otherwise finish assessment, the optimal process time of output loss (minute) value OPM$
PnWith optimal process time of remainder (minute) OPMR
Pn(being that those are also not evaluated).Step S78.
B. be evaluated at production run part shut down time of a problem p among the BTP:
One shut down time problem expense form by two parts.First also is that most important parts occurs in and can utilize the place of going to produce the unit that more can sell originally lost time originally.If there are not or have only some units to sell, then the remaining part of loss shut down time is the labour's expense when production run stops.
Referring now to Figure 23.The first step be determine in BTP since production run lost how many optimal process time shut down time (hour).From database retrieval one day and one class for variant v because DT shut down time that problem causes
Pvsd(it is input when finishing for one class).Step S80.In BTP, this is added up, provide DT shut down time for a variant v owing to problem p
PvnStep S82.By with DT
PvnMultiply by in BTP real process efficiency TPE for a specific variant
Vn, find during underlying table in for variant v since from optimal process time of loss shut down time of a problem p (hour) quantity D TOP
PvnProcess S84.
Real process efficiency is for the processing hourage OPH of the best of variant v in BTP
VnDivided by processing hourage APH actual in BTP
VnStep S88.At data input phase input APH
VnBy will be in BTP the output O of variant
VnKey link speed MBS divided by maximum
vFind OPH
VnStep S86.
Repeat this process for all variants.By with the DTOP on all variants
PvnAdd up and find because the processing hourage DTOP of the best of the total loss of problem p shut down time
PnStep S90.With these minutes value be input in the program module of loss cost of products Evaluation Method and and assess them.Step S92.See also Figure 22.
The second portion of shut down time loss be loss working time (hour).By in BTP will the working time in each production run (hour) loss add up find the loss working time (hour).For loss working time of a production run (hour) with shut down time problem whether also be to change in that operating overstaffed problem relevantly.If shut down time, problem also was an overstaffed problem, then the loss working time of shut down time (hour) DTLL
Pvn1Be because DT shut down time that problem p causes
Pvsd, actual personnel amount ACS
VsdWith real process efficiency TPE
VnProduct.Step S96.If shut down time, problem was not an overstaffed problem, then the loss working time of shut down time (hour) DTLL
Pvn2Be because DT shut down time that problem p causes
Pvsd, best personnel amount ACS
VsdWith real process efficiency TPE
VnProduct.Step S96.Calculate these values for each production run, and with they add up provide for a specific problem in BTP for the work loss DTLL of total shut down time of variant v
PvnStep S98.Then with the DTLL of all variants
PvnAdd up, provide because the work loss DTLL of total shut down time that problem p causes
PnStep S100.
We will remember the loss cost of products Evaluation Method program module output optimal process time of a shut down time (minute) value DTOPM$
PnWith since market situation decision to each variant can only sell that the such fact of fixed amount causes can not be evaluated a time quantum DTOPMR
PnIn the following manner that those are remaining process time (minute) assess as the labor hours of loss.At first, step S102 by with the process time of remainder (minute) DTOPMR
PnDivided by total loss DTOPM process time owing to shut down time, problem p caused
Pn(calculating at step S90 in the past) determine remaining not loss working time of assessment (hour) ratio.The ratio DT of the shut down time that to not assess then
PnMultiply by because the labour of total shut down time that problem p causes loses DTLL
Pn, and then multiply by total labour productivity AULR for production run.Step S104.This has provided because the value DTLL$ of total work loss that shut down time, problem p caused
Pn
On BTP shut down time problem p total value DT$
PnBe because the value DTOPM$ of optimum process the number of minutes of the loss that this problem causes
PnValue DTLL$ with the work of losing
PnAnd.Step S106.
C. the process that is evaluated at a problem p among the BTP is moved part slowly:
As one shut down time problem situation in, one is caused slowly the problem of operation that two possible expense parts are arranged: the expense of the expense of loss product and waste work.
, must find when BTP owing to move the expense of the product loss that causes slowly in order to assess owing to the problem optimal process total amount of the loss of time.For single production run operation, how many production units of variant v find because the optimal process time of a slow operation problem loss because problem can not be produced by at first determining.
By obtaining and DT for adding up total shut down time of all problems
Vn(the step S108 in Figure 23) is with this with divided by APH process time of the reality in BTP
VnDeduct this result from 1 again and find proportional production run uptime UT when production run is moved
VnStep S110, Figure 23.
At first proportional production run uptime multiply by actual APH process time by will work as production run the time
VsdCalculating is for the optimal process time of variant v owing to slow operation problem p loss.The result be multiply by the maximum key link speed MBS of the variant of production run
vKey link speed ABS with reality
VsdBetween poor.By with the result divided by maximum key link speed MBS
vMultiply by actual production run efficient TPE then
Vn, the result is converted to the optimal process time SROPM of loss
PvsdStep S120.See also Figure 24.
The production run of identical slow operation problem takes place then with SROPM for all in BTP
PvsdAdd up, be given among the BTP because the optimal process time SROPM of the total loss of slow operation problem p
PnStep S122.
In order to assess SROPM
Pn, we send it into loss cost of products Evaluation Method program module, as shown in figure 22.Step S124.Because the value of the resulting loss product that slow operation problem causes is SROPM$
Pn(promptly lose the output OPM$ of cost of products Evaluation Method program module
Pn).If there is the not optimal process time SROPMR of the loss of assessment of any remainder
Pn(promptly lose the output OPMR of cost of products Evaluation Method program module
PnGreater than zero), then in a kind of mode that will be described now as the working time of loss it being assessed.
By with SROPMR
PnOptimal process time SROPM divided by the total loss that in BTP, causes owing to problem p
PnDetermine the also ratio of the process time of not evaluated loss.Step S126.Below, calculate because the total amount in working time of the loss that slow operation problem p causes.For each production run, the optimal process time of loss (hour) amount be SROPM
Pvsd, it calculates at step S120.By it being multiply by personnel amount ACS for the variant reality of producing
VsdIf slow operation problem with identical with that overstaffed problem in the class in that day, does not convert this SRLL in working time of loss to
PvsdStep S128.If operation problem is with identical with that overstaffed problem in the class in that day slowly, then Sun Shi SRLL in working time
Pvsd2Be SROPM
PvsdMultiply by personal best's quantity OCS
VsdStep S130.This has been avoided the dual calculating in the working time of loss.For each the production run repeating step S120 in the BTP that slow operation problem takes place, S128 and S130 are with resulting SRLL
PvsdValue add up and provide because the SRLL in working time of total loss that slow operation problem p causes
PnStep S132.
Since the dollar value in the working time of slow operation problem p loss be do not lost the optimal process time that the cost of products Evaluation Method assesses (hour) ratio SRP
Pn, owing to the SRLL in working time of the total loss of slow operation problem
PnProduct with total labour productivity AULR.This value is called SRLL$
PnStep S134.
By losing product section SROPM$
PnReally with loss work part SRLL$
PnTotal dollar value SR$ of operation part is slowly determined in addition
PnStep S136.
D. the calculating of the key link waste product of problem p part in BTP:
The key link waste product be in key link or after key link, produce but the product that must go out of use.As in the situation of all shut down times and slow operation problem, key link waste product value is by two parts, and product loss and work loss are formed.
With reference to Figure 25.Following assessment product loss: the quantity BWU of the production unit by will becoming waste product
PvsdDivided by maximum key link speed MBS for variant
vWith multiply by real production run efficient TPE
v, calculate in a specific production run because the optimal process that key link waste product problem p causes is measured BWOPM the loss of time
PvsdStep S140.By the unit quantity (" WasteQty of unaccepted variant in key link or after key link that will determine at the data input phase
Vsd") multiply by in the spoiled goods report position of dummy run phase input and arrive the production unit factor (" WRUtoPU
Pv"), calculate BWU
VsdFor all production runs in the BTP that key link waste product problem p takes place with BWOPM
PvsdAdd up, provide because the total optimal process that key link waste product problem p causes is measured BWOPM the loss of time
PnStep S142.
Then with BWOPM
PnSend into loss cost of products Evaluation Method program module (being also referred to as " the assessment box of being produced restriction "), it is the optimal process time of assessment of loss as much as possible, and output BWOPM$
PnStep S144.With another output, remaining loss BWOPMR process time
PnAssess working time as loss.
At first, by with BWOPMR
PnDivided by the total optimal process BWOPM loss of time that causes owing to key link waste product problem p
PnCalculate the ratio of the optimal process time of also not evaluated loss, provide BWP
PnStep S146.Secondly, calculate since key link waste product problem p in single production run total loss labour time (hour).If key link waste product problem is then passed through BWOPM with too much personnel's problem is identical
PvsdMultiply by personal best's quantity OCS
vWill be in a specific production run because the optimal process that key link waste product problem p cause is measured BWOPM the loss of time
PvsdConvert to loss process time (hour) BWLL
Pvsd1, see also step S148.If key link waste product problem is not identical with too much personnel's problem, then with BWOPM
PvsdMultiply by actual personnel amount ACS
PvsdProvide BWLL
Pvsd2Step S150.BWLL
Pvsd1And BWLL
Pvsd2Be in a specific production run or order of classes or grades at school s and date d, because key link waste product problem p loses the total amount in working time.Also can pass through BWU
PvsdDivided by MBS
vCalculate BWOPM
Pvsd
By to all production runs in BTP with BWLL
Pvsd1Or BWLL
Pvsd2Addition provides because total loss BWLL in working time that key link waste product problem p causes
PnStep S152.By it be multiply by because the ratio BWP in the key link waste product problem p of assessment loss working time of causing not
Pn(seeing also step S146) and total labour productivity AULR assess this, cause BWLL$
PnStep S154.By optimal process time value BWOPM$ with loss
PnWork value BWLL$ with loss
PnThe total value of addition calculation key link waste product problem p in BTP causes BW$
PnStep S156.
4. be evaluated at the waste starting material part of problem p among the BTP:
With reference to Figure 26.For each starting material of in BTP, wasting, the starting material total amount WasteQty that will in BTP, waste owing to problem p
Pvsd(in the input of data input phase) multiply by the spoiled goods report position to waste of raw materials conversion factor (" WRUtoRU
Pv"), measure (" RWQty for raw-material one that provides waste
Pnr").Step S160.With RWQty
PnrMultiply by the dollar value RW$ of the single unit of material
Pnr(in dummy run phase input) provides the sort of raw-material value " RW$ of waste
r".Step S162.Former material material to all kinds that uses repeats this computing, then they is added up, and is given among the BTP because the raw-material total value RW$ of problem p waste
PnStep S164.
5. will in BTP, the total value of problem p add up:
All parts of the expense of problem p now in BTP, have been determined.By with all parts, promptly overstaffed value XCLL$
PnThe value DT$ of shut down time
Pn, Yun Hang value SR$ slowly
Pn, the value BW$ of key link waste product
PnAnd all raw-material value RW$
PnAdd up, find the total value of problem, give the total value PROB$ of the p that goes wrong
PnStep S170 among Figure 27.
6. ask the expense of problem p in a year with extrapolation method:
Pass through PROB$ now
PnMultiply by for 52 week mutually and divided by the number of weeks in BTP, 5 week typically is with PROB$
PnBe extrapolated to a year and a day from BTP.The result obtains the total value PROB$ of problem p in a year and a day
pStep S172 in Figure 27.With PROB$
pBe kept in the table of database.Step S174.
7. for all problems repeating step 1-8 in the production run in BTP:
The all steps that repeat just to have described for all problems in the production run.Step S176 and S178.
With total value to the classify priority list of the problem of setting up of all problems:
Now all results that are stored in the table are classified, making has the problem of mxm. to be in the top of table and with all problems of the sequential storage remainder of successively decreasing of value.Step S180.Here it is " priority list of problem ".Print the priority list of problem then.Step S182.Then the administrative authority of factory can determine to solve in all problems which and distribute all resources according to the value of all problems.Step S184.
Though we have described the present invention with reference to its preferential embodiment, those common those skilled in the art understand and can make all different modifications and do not depart from spirit of the present invention or limited its scope preferential embodiment.
Applicability in industry
Those skilled in the art will understand that method of the present invention and computer system make production process, and particularly the efficient of manufacture process reaches maximum aspect important application.
Claims (39)
1. the method that the production run of a production product is controlled designs production run it can be moved under an optimum performance, and this method comprises following all steps:
A problem in the identification production run, this problem is moved production run under the performance than optimum performance difference;
Determine the process time of an available the best;
What determine because the process time of problem loss available the best;
A finance value of computational problem; With
Priority according to the finance value problem identificatioin of problem.
2., then can be used for production run how many process times if the process of claim 1 wherein that the step of determining an available optimal process time comprises determines that production run moves under optimum performance.
3. the method for claim 2 determines that production run moves if it comprises under optimum performance, if produce in the process time of production run can be used for, the step what can sell is away arranged in the product of then producing.
4. any one method in the claim 1 to 3, wherein the step of the finance value of computational problem comprises according to because how many process times are the problem production run lose, the step that problem is assessed.
5. the method for claim 4, wherein the step of the finance value of computational problem comprises the boundary profit of all products of producing according to production run, to because the step of assessing the process time of problem production run loss.
6. the method for claim 4, wherein the step of the finance value of computational problem comprises according to labour's expense because the step of assessing the process time of problem production run loss.
7. any one method in the claim 1 to 3, wherein the step of the finance value of computational problem comprises and determines whether production run is the step of being produced restriction.
8. any one method in the claim 1 to 3, wherein the step of the finance value of computational problem comprises and determines whether production run is the step of being sold restriction.
9. the method for claim 7, the boundary profit of all products of producing according to production run wherein, to determining that production run is the degree of being produced restriction, that degree because the loss of problem production run is arrived process time is assessed.
10. claim 5 or 9 method further comprise, if not according to the boundary profit of product to not assessing any process time of production run loss, the step of being assessed the process time of remainder according to labour's expense then.
11. any one method in the claim 7 to 9 wherein according to labour's expense, to determining that production run is the degree of being sold restriction, because the problem production run is lost that degree of arriving process time, is assessed.
12. the method for claim 4 is wherein determined because the step of what of problem loss comprises available optimal process time determines owing to make production run move to such an extent that lose the steps of how many process times than the slow problem production run of expectation.
13. the method for claim 4 is wherein determined because the step of how much available optimal process time of problem loss comprises definite owing to make production run problem production run out of service lose the step of how many process times.
14. the method for claim 4, wherein determine because the step of how much available optimal process time of problem loss comprises an identification key link in process of production, this key link has limited a maximal rate of production run operation and has determined because the problem production run that makes product become waste product in key link or after key link is lost the step of how many process times.
15. the process of claim 1 wherein the step of one of computational problem finance value comprises by considering to need how many supernumerarys to operate production run owing to problem, the step that problem is assessed.
16. the process of claim 1 wherein the step of one of computational problem finance value comprises by considering need use how many starting material owing to the problem production run, the step that problem is assessed.
17. any one method in the claim 1 to 16, it comprises a key link in the identification production run, and this key link has determined the maximal rate of production run operation.
18. the method for claim 17, it comprises that problem identificatioin is to production run Effect on Performance in key link.
19. the method for claim 18, wherein the step of computational problem finance value comprises and considering a problem to production run Effect on Performance in key link.
20. the method for claim 18, wherein problem identificatioin comprises the step of at length determining the position of the problem relevant with key link to the step of production run Effect on Performance in key link.
21. the method for claim 20, wherein the step of the position of problem identificatioin comprises that problem identificatioin is in key link, still in the step after the key link or before key link.
22. the method for claim 21 is wherein determined to comprise the step of determining to lose owing to the problem production run that makes product become waste product how many process times in key link or after key link because the problem production run is lost the step of how many process times.
23. any one method in the claim 20 to 22 determines that wherein the step of losing how many process times owing to the problem production run comprises definite owing to make key link problem production run out of service lose the step of how many process times.
24. any one method in the claim 20 to 23 is wherein determined because the problem production run is lost the step of how many process times comprises and determining owing to make key link move to such an extent that lose the steps of how many process times than the slow problem production run of expectation.
25. any one method in the claim 20 to 23 is wherein determined because the problem production run is lost the step of how many process times and comprised following all steps:
Determine a slow working time for expression owing to make key link lose the problem of how many process times with the problem production run of a speed operation slower than maximal rate;
Determine a shut down time for representing problem owing to making key link problem production run out of service lose how many process times; With
Because losing the problem of how many process times, the problem production run that makes product become waste product determines a key link waste product time for expression in key link or after key link.
26. the method for claim 25, wherein all steps of computational problem finance value comprise for problem and determine slow working time, the step that all finance of shut down time and key link waste product time are worth.
27. the method in the claim 1 to 26 described in any one, wherein discern a plurality of problems in process of production, these problems are moved production run under the performance than optimum performance difference, determine that because each problem loss how many available optimal process times calculating is for the finance value of each problem and determine the priority of all problems according to the finance value of each problem in a plurality of problems.
28. any one method in the claim 1 to 27, it further comprises the step of whether correcting certain problem or each problem according to the finance value decision of certain problem or each problem.
29. any one method in the claim 1 to 28, it further comprises the step of distributing all resources according to the finance value of certain problem or each problem to certain problem or each problem.
30. the method that the production run of a production product is controlled, it is basically as here being described with reference to appended all figure.
31. method that the production run of a production product is controlled, the design production run is moved it under optimum performance, wherein production run is moved under the performance than optimum performance difference because of a plurality of production runes that make, thereby the problem that makes production run lose process time is suffered infringement, and this method comprises following all steps:
An identification key link in process of production, this key link have limited a maximal rate of production run operation;
Calculate a finance value of each problem in a plurality of problems, it comprises:
Determine that a problem is to the production run Effect on Performance in key link; With
According to a problem production run Effect on Performance in key link is assessed this problem.
32. the method that the production run of a production product is controlled, the design production run is moved it under optimum performance, and this method comprises following all steps:
An identification problem in process of production, this problem is moved production run under the performance than optimum performance difference;
An identification key link in process of production, this key link have determined the maximal rate of production run operation;
Determine a slow working time for expression owing to make key link lose the problem of how many process times with a problem production run than the slow-footed speed operation of expectation;
Determine a shut down time for representing problem owing to making key link problem production run out of service lose how many process times;
Because losing the problem of how many process times, the problem production run that makes product become waste product determines a key link waste product time for expression in key link or after key link;
Determine slow working time for problem, all finance values of shut down time and key link waste product time;
According to the slow working time for problem, all finance values problem identificatioin of shut down time and key link waste product time reduces the profit of how many production runes; With
Reduce the priority of the profit problem identificatioin of how many production runes according to problem.
33. the method that the production run of a production product is controlled, the design production run is moved it under optimum performance, and this method comprises following all steps:
An identification problem in process of production, this problem is moved production run under the performance than optimum performance difference, thereby makes production run lose turnout;
Determine because how many turnout are problem lost;
Move under optimum performance if determine production run, what have can sell away in the product of then producing;
If, what have can sell away in the product of then producing, problem is assessed a finance value of computational problem by according to because how many turnout are problem lose and production run is moved under the boundary profit of optimum performance and product.
34. a computer system is carried out program design in order to be implemented in the claim 1 to 33 method described in any one to this computing machine.
35. the computer system of claim 34, it comprises:
Be used to import the simulated data relevant, thereby set up the device of a computer model of production run with production run;
Be used to import the device that monitors the performance data that obtains by performance to production run;
Be used for determining the device of a finance value of a problem of certain problem or a plurality of problems, it comprises:
Be used for determining the device of an available optimal process time, if this device comprises that being used for definite production run moves, and then has to can be used for the device that production run removes to produce product how many process times under optimum performance;
Be used for determining one because the device of the amount of the available optimal process time of problem loss;
Be used for basis because the device that the amount of the available optimal process time of problem loss is assessed this problem; With
Be used for exporting the device of finance value of each problem of certain problem or a plurality of problems.
36. the computer system of claim 35, it further comprises a key link that is used to discern in process of production, this key link has limited the maximal rate of production run operation, device and the device of finance values that wherein is used for a problem of definite certain problem or a plurality of problems comprise:
Be used for determining that a problem is to the device in the production run Effect on Performance of key link;
The device of production run Effect on Performance in key link being assessed problem according to a problem.
37. the computer system of claim 34, it further comprises and is used for being implemented in claim 4 to 29 or certain step of 31 to 33 any one methods or the device of all steps.
38. a computer system, it is basically as here being described with reference to appended all figure.
39. one is used for computer system that a production run of producing product is controlled, the design production run is moved it under optimum performance, wherein production run is moved under the performance than optimum performance difference because of a plurality of production runes that make, thereby the problem that makes production run lose process time is suffered infringement, and computer system comprises:
Be used to import the simulated data relevant, thereby set up the device of a computer model of production run with production run;
Be used to import the device that monitors the performance data that obtains by performance to production run;
Be used to discern a key link in process of production, this key link has limited the device of a maximal rate of production run operation;
Be used for calculating the device of a finance value of each problem of a plurality of problems, it comprises:
Be used for determining that a problem is to the device in the production run Effect on Performance of key link; With
The device of production run Effect on Performance in key link being assessed problem according to a problem.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/027,098 | 1998-02-20 | ||
| US09/027,101 | 1998-02-20 | ||
| US09/027,101 US6128540A (en) | 1998-02-20 | 1998-02-20 | Method and computer system for controlling an industrial process using financial analysis |
| US09/027,098 US6144893A (en) | 1998-02-20 | 1998-02-20 | Method and computer system for controlling an industrial process by analysis of bottlenecks |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN1291312A true CN1291312A (en) | 2001-04-11 |
Family
ID=26702048
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN99803098A Pending CN1291312A (en) | 1998-02-20 | 1999-02-22 | Method and system for controlling processes |
Country Status (8)
| Country | Link |
|---|---|
| EP (1) | EP1055186A4 (en) |
| JP (1) | JP2002504726A (en) |
| KR (1) | KR20010041058A (en) |
| CN (1) | CN1291312A (en) |
| AU (1) | AU724154B2 (en) |
| CA (1) | CA2321283A1 (en) |
| GB (1) | GB2337835B (en) |
| WO (1) | WO1999042939A1 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104199300A (en) * | 2003-07-30 | 2014-12-10 | 费舍-柔斯芒特系统股份有限公司 | Process control system utilising economic models |
| CN106054827A (en) * | 2015-03-20 | 2016-10-26 | 因文西斯系统公司 | Asset management in a process control system |
| US9760651B2 (en) | 2002-04-15 | 2017-09-12 | Fisher-Rosemount Systems, Inc. | Web services-based communications for use with process control systems |
| CN110506283A (en) * | 2017-04-14 | 2019-11-26 | 横滨橡胶株式会社 | The management system of conveyer belt |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP4502414B2 (en) * | 1998-04-09 | 2010-07-14 | Ｏｋｉセミコンダクタ株式会社 | Production management information output device and production management information output method |
| US7032816B2 (en) | 2001-12-28 | 2006-04-25 | Kimberly-Clark Worldwide, Inc. | Communication between machines and feed-forward control in event-based product manufacturing |
| US7035877B2 (en) | 2001-12-28 | 2006-04-25 | Kimberly-Clark Worldwide, Inc. | Quality management and intelligent manufacturing with labels and smart tags in event-based product manufacturing |
| US7380213B2 (en) | 2001-12-28 | 2008-05-27 | Kimberly-Clark Worldwide, Inc. | User interface for reporting event-based production information in product manufacturing |
| US7357298B2 (en) | 2001-12-28 | 2008-04-15 | Kimberly-Clark Worldwide, Inc. | Integrating event-based production information with financial and purchasing systems in product manufacturing |
| US8799113B2 (en) | 2001-12-28 | 2014-08-05 | Binforma Group Limited Liability Company | Quality management by validating a bill of materials in event-based product manufacturing |
| US6968250B2 (en) | 2001-12-28 | 2005-11-22 | Kimberly-Clark Worldwide, Inc. | Intelligent agent system and method for evaluating data integrity in process information databases |
| KR100473065B1 (en) * | 2002-03-25 | 2005-03-09 | 주식회사 에코시안 | Priority setting method for life cycle assessment |
| US7218974B2 (en) | 2005-03-29 | 2007-05-15 | Zarpac, Inc. | Industrial process data acquisition and analysis |
| KR100973239B1 (en) * | 2008-03-24 | 2010-08-04 | 오경자 | Earring for stimulating spots on the body suitable for acupuncture |
| JP6981061B2 (en) * | 2017-06-26 | 2021-12-15 | 富士通株式会社 | Production plan generation program, production plan generation method and production plan generation device |
| US10976712B2 (en) * | 2018-02-05 | 2021-04-13 | Honeywell International Inc. | Method and system to provide cost of lost opportunity to operators in real time using advance process control |
| WO2022172362A1 (en) * | 2021-02-10 | 2022-08-18 | 株式会社日立製作所 | Business management device, business management method, and business management program |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH09136246A (en) * | 1995-09-12 | 1997-05-27 | Toyota Motor Corp | Method and device for evaluation of optimum indication point |
| US5946661A (en) * | 1995-10-05 | 1999-08-31 | Maxager Technology, Inc. | Method and apparatus for identifying and obtaining bottleneck cost information |
| JPH09305665A (en) * | 1996-05-15 | 1997-11-28 | Matsushita Electric Ind Co Ltd | Part cost estimating device |
| US5838565A (en) * | 1997-05-15 | 1998-11-17 | Vanguard International Semiconductor Corporation | Manufacturing control method for IC plant batch sequential machine |
| TW330302B (en) * | 1997-06-25 | 1998-04-21 | Vanguard Int Semiconduct Corp | Wafer output control and management method and system in an IC plant |
-
1999
- 1999-02-22 WO PCT/AU1999/000098 patent/WO1999042939A1/en not_active Application Discontinuation
- 1999-02-22 JP JP2000532804A patent/JP2002504726A/en active Pending
- 1999-02-22 CA CA002321283A patent/CA2321283A1/en not_active Abandoned
- 1999-02-22 GB GB9917270A patent/GB2337835B/en not_active Expired - Lifetime
- 1999-02-22 CN CN99803098A patent/CN1291312A/en active Pending
- 1999-02-22 AU AU30181/99A patent/AU724154B2/en not_active Expired
- 1999-02-22 EP EP99911511A patent/EP1055186A4/en not_active Withdrawn
- 1999-02-22 KR KR1020007009095A patent/KR20010041058A/en not_active Application Discontinuation
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9760651B2 (en) | 2002-04-15 | 2017-09-12 | Fisher-Rosemount Systems, Inc. | Web services-based communications for use with process control systems |
| CN104199300A (en) * | 2003-07-30 | 2014-12-10 | 费舍-柔斯芒特系统股份有限公司 | Process control system utilising economic models |
| CN104199300B (en) * | 2003-07-30 | 2017-03-22 | 费舍-柔斯芒特系统股份有限公司 | Process control system utilising economic models |
| CN106054827A (en) * | 2015-03-20 | 2016-10-26 | 因文西斯系统公司 | Asset management in a process control system |
| CN110506283A (en) * | 2017-04-14 | 2019-11-26 | 横滨橡胶株式会社 | The management system of conveyer belt |
Also Published As
| Publication number | Publication date |
|---|---|
| WO1999042939A1 (en) | 1999-08-26 |
| JP2002504726A (en) | 2002-02-12 |
| AU724154B2 (en) | 2000-09-14 |
| CA2321283A1 (en) | 1999-08-26 |
| KR20010041058A (en) | 2001-05-15 |
| GB2337835B (en) | 2000-07-19 |
| EP1055186A4 (en) | 2001-11-07 |
| EP1055186A1 (en) | 2000-11-29 |
| GB2337835A (en) | 1999-12-01 |
| AU3018199A (en) | 1999-09-06 |
| GB9917270D0 (en) | 1999-09-22 |
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