Hierarchical methodology for productivity measurement and improvement of productions systems
First Claim
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1. A hierarchical method for causally relating productivity to a production system to provide an integrated productivity analysis of the system, comprising:
- a) identifying an array of production operations including any one or more of the following;
process, transportation and storage;
b) modeling the system as an interconnected array of unit production processes (UPP) reflecting actual or desired material flow sequence through the system;
c) applying at least one set of UPP interconnections to factor the system into at least one set of UPP subsystems for description and analysis; and
d) assessing each UPP and each subsystem to calculate at least one productivity metric of each UPP, UPP subsystem and the system.
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Abstract
A hierarchical method, computer system, and computer product for causelly relating productivity to a production system to provide an integrated analysis of the system which measures, monitors, analyses and, optionally, simlates performance of the production system based on a common set of productivity metrics for throughput effictiveness, cycle time effectiveness, throughput and inventory (FIG. 5, C(ma), P(m), L(in), P(a), L(out), P(out), C(md)).
95 Citations
104 Claims
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1. A hierarchical method for causally relating productivity to a production system to provide an integrated productivity analysis of the system, comprising:
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a) identifying an array of production operations including any one or more of the following;
process, transportation and storage;
b) modeling the system as an interconnected array of unit production processes (UPP) reflecting actual or desired material flow sequence through the system;
c) applying at least one set of UPP interconnections to factor the system into at least one set of UPP subsystems for description and analysis; and
d) assessing each UPP and each subsystem to calculate at least one productivity metric of each UPP, UPP subsystem and the system. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method for hierarchical representation of a production system for measuring, monitoring, analyzing and/or simulating production performance of the production system based on a common set of productivity metrics for throughput effectiveness, cycle time effectiveness, throughput and inventory, comprising:
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a) identifying an array of production operations including any one or more of the following;
process, transportation, and storage;
b) providing a description of the production system as an interconnected array of unit production processes (UPP) reflecting an actual material flow sequence through the system;
c) applying at least one set of UPP subsystems to factor an overall system flowchart into UPP subsystems, and combining the subsystems to represent the overall production system;
d) analyzing productivity metrics of each UPP, each UPP subsystem, and the overall system; and
e) converting the overall system flowchart to a discrete event simulation description, and enabling comparative performance assessment of various production scenarios useful for performance improvement and system design. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41)
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42. A method for analysis of system level productivity comprising:
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a) establishing a unique layout or architecture for arranging at least one set of unit production processes (UPPs) in a complex system;
b) calculating overall equipment effectiveness (OEE) and, optionally, other parameters of individual UPP'"'"'s;
c) calculating overall throughput effectiveness (OTEF) of the UPP subsystems and the system;
d) calculating good production output (PG(F)) of the UPP subsystems and the system;
e) calculating cycle time efficiency (CTEF) of the UPP subsystems and the system; and
f) calculating factory level inventory (LF) of the UPP subsystems and the system. - View Dependent Claims (43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63)
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64. A computer system for relating productivity to a production system to provide an integrated productivity analysis of the system comprising:
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a) identifying an array of production operations including any one or more of the following;
process, transportation and storage;
b) modeling the system as an interconnected array of unit production processes (UPP) reflecting actual or desired material flow sequence through the system;
c) applying at least one set of UPP interconnections to factor the system into at least one set of UPP subsystems for description and analysis; and
d) assessing each UPP and each subsystem to calculate at least one productivity metric of each UPP, UPP subsystem and the system. - View Dependent Claims (65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83)
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84. A computer system for hierarchical representation of a production system for measuring, monitoring, analyzing and/or simulating production performance of the production system based on a common set of productivity metrics for throughput effectiveness, cycle time effectiveness, throughput and inventory, comprising:
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a) identifying an array of production operations including any one or more of the following;
process, transportation, and storage;
.b) providing a description of the production system as an interconnected array of unit production processes (UPP) reflecting an actual material flow sequence through the system;
c) applying at least one set of UPP subsystems to factor an overall system flowchart into UPP subsystems, and combining the subsystems to represent the overall production system;
d) analyzing productivity metrics of each UPP, each UPP subsystem, and the overall system; and
e) converting the flowchart to a discrete event simulation description, and enabling comparative performance assessment of various production scenarios useful for performance improvement and system design.
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85. A computer program product comprising a program storage device readable by a computer system tangibly embodying a program of instructions executed by the computer system to perform in a process for causally relating productivity to a production system, the process comprising:
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a) identifying an array of production operations including any one or more of the following;
process, transportation and storage;
b) modeling the system as an interconnected array of unit production processes (UPP) reflecting actual or desired material flow sequence through the system;
c) applying at least one set of UPP interconnections to factor the system into at least one set of UPP subsystems for description and analysis; and
d) assessing each UPP and each subsystem type to calculate at least one productivity metric of each UPP, UPP subsystem and the system. - View Dependent Claims (86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104)
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Specification