SYSTEM AND METHOD FOR THE PRODUCTION OF GOODS OR PRODUCTS

• US 20080077266A1
• Filed: 08/23/2007
• Published: 03/27/2008
• Est. Priority Date: 08/25/2006
• Status: Active Grant

• Current Assignee: I-Factory Inc.
• Original Assignee: I-Factory Inc.
• Inventors: Thierauf, Rainer
• Granted Patent: US 7,715,936 B2
• Time in Patent Office: Days
• US Class Current: 700/99
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202

Abstract

A computer-based system and method for production planning are described that relies on developing factory shop floor modeling. This modeling includes simulating the factory shop floor to create a Virtual Factory. This Virtual Factory provides the ability to assess any possible production sequence for determining an optimal of production sequence according to the criteria defined the user.

Claims

1. A method for optimizing a production process comprising the steps of:

(A) creating a representation for equipment for production of a product and arranging the representation in at least one sequence for production of the product, and designating each piece of equipment as a resource type according to such piece of equipment'"'"'s function;

(B) selecting the sequence created at step (A) and designating such sequence as a current sequence;

(C) calculating a value score for the current sequence according to values assigned to each resource in the current sequence as resources are arranged in the current sequence, with the value scores being assigned at least in consideration of characteristics of each resource;

(D) determining if there are possible unevaluated variations in the arrangement of the resources in the current sequence, and if there are no possible unevaluated variations then designating the current sequence an optimal sequence and proceeding to step (G), and if there are possible unevaluated variations, varying the arrangement of resources in the current sequence to create a new sequence;

(E) calculating a value score for the new sequence according to values assigned to each resource in the new sequence as resources are arranged in the new sequence, with the values being assigned at least according to resource characteristics;

(F) comparing the value scores for the current sequence and the new sequence to determine if the value score for the new sequence exceeds the value score for the current sequence according to predetermined criteria, and if the value score for the new sequence exceeds the value score for the current sequence, then designating the new sequence as the current sequence and proceeding to step (D), and if the value score for the current score exceeds the value score for the new sequence, then retaining the current sequence as the current sequence and proceeding to step (D); and

(G) returning to a system user the optimal sequence for production of the product.

2. The method as recited in claim 1, wherein the representation of the production includes a computer-based representation of the equipment and the arrangement of such equipment.

3. The method as recited in claim 2, wherein the computer-based representation includes a virtual representation of the equipment and the arrangement of such equipment.

4. The method as recited in claim 1, wherein resource characteristics for a resource include restrictions associated with the operation of such resource.

5. The method as recited in claim 4, wherein the restrictions include restrictions associated with interaction of resources.

6. The method as recited in claim 1, wherein calculating a value score for the current sequence, further includes the substeps of:

(A) selecting the last resource in the current sequence and designating such resource as the current resource;

(B) determining if there is another resource upstream in the current sequence and if there is an upstream resource, selecting the upstream resource and designating such upstream resource as the current resource, and repeating step (B) until an upstream resource is not identified, then proceeding to step (C); and

(C) calculating a value score for the current sequence based on a composite of the assigned values of each of the resources of the current sequence selected at steps (A) and (B).

7. The method as recited in claim 1, wherein calculating a value score for the current sequence, further includes the substeps of:

(A) selecting the last resource in the new sequence and designating such resource as the new resource;

(B) determining if there is another resource upstream in the new sequence and if there is an upstream resource, selecting the upstream resource and designating such upstream resource as the new resource, and repeating step (B) until an upstream resource is not identified, then proceeding to step (C); and

(C) calculating a value score for the new sequence based on a composite of the assigned values of each of the resources of the sequence selected at steps (A) and (B).

8. The method as recited in claim 6 or 7, wherein assigning a value to each resource includes a value based on at least a time score, energy score and/or human resource score for that resource.

9. The method as recited in claim 8, wherein the method is capable of calculating a value score for a sequence at any point in time during operation of that sequence.

10. The method as recited in claim 1, wherein the method is capable of calculating a value score for a sequence that processes products in batch form.

11. A method for calculating a value score for a production sequence that contains a plurality of pieces of equipment comprising the steps of:

(A) designating each piece of equipment as a resource type according to such piece of equipment'"'"'s function;

(B) selecting the last resource in the sequence and designating such resource as a current resource;

(C) determining if there is another resource upstream in the sequence and if there is an upstream resource, selecting the upstream resource and designating such upstream resource as the current resource, and repeating step (C) until an upstream resource is not identified, then proceeding to step (D);

(D) calculating a value score for the sequence based on a composite of assigned values for each of the resources selected at steps (B) and (C) for the sequence;

(E) returning to a system user a calculated value score for the sequence.

12. The method as recited in claim 11, wherein assigning a value to each resource includes a value based on at least a time score, energy score and/or human resource score for that resource.

13. The method as recited in claim 11, wherein the method is capable of calculating a value score for the sequence at any point in time during operation of that sequence.

14. The method as recited in claim 11, wherein the method is capable of calculating a value score if the sequence processes products in batch form.

15. A computer-base system for optimizing a production process comprising:

(A) means for creating a representation of equipment for production of a product and arranging the representation in at least one sequence for production of the product, and means for receiving a designation for each piece of equipment as a resource type according to such piece of equipment'"'"'s function;

(B) means for selecting the sequence created at step (A) and designating such sequence as a current sequence;

(C) means for calculating a value score for the current sequence according to values assigned to each resource in the current sequence that are received by the system as resources are arranged in the current sequence, with the value scores being assigned at least in consideration of characteristics of each resource;

(D) means for determining if there are possible unevaluated variations in the arrangement of the resources in the current sequence, and if there are no possible unevaluated variations then designating the current sequence an optimal sequence and proceeding to step (G), and if there are possible unevaluated variations, varying the arrangement of resources in the current sequence to create a new sequence;

(E) means for calculating a value score for the new sequence according to values assigned to each resource in the new sequence as resources are arranged in the new sequence, with the values being assigned at least according to resource characteristics;

(F) means for comparing the value scores for the current sequence and the new sequence to determine if the value score for the new sequence exceeds the value score for the current sequence according to predetermined criteria, and if the value score for the new sequence exceeds the value score for the current sequence, then designating the new sequence as the current sequence and proceeding to step (D), and if the value score for the current score exceeds the value score for the new sequence, then retaining the current sequence as the current sequence and proceeding to step (D); and

(G) means for returning to a system user the optimal sequence for production of the product.

16. The system as recited in claim 15, wherein the means for creating the representation of the production includes a computer-based representation of the equipment and the arrangement of such equipment.

17. The system as recited in claim 16, wherein the computer-based representation includes a virtual representation of the equipment and the arrangement of such equipment.

18. The system as recited in claim 15, wherein resource characteristics for a resource include restrictions associated with the operation of such resource.

19. The system as recited in claim 18, wherein the restrictions include restrictions associated with interaction of resources.

20. The system as recited in claim 15, wherein the means for calculating a value score for the current sequence, further includes computer-based:

(A) means for selecting the last resource in the current sequence and designating such resource as a current resource;

(B) means for determining if there is another resource upstream in the current sequence and if there is an upstream resource, selecting the upstream resource and designating such upstream resource as the current resource, and repeating step (B) until an upstream resource is not identified, then proceeding to step (C); and

(C) means for calculating a value score for the current sequence based on a composite of the assigned values of each of the resources of the current sequence selected at steps (A) and (B).

21. The system as recited in claim 15, wherein the means for calculating a value score for the current sequence, further includes computer-based:

(A) means for selecting the last resource in the new sequence and designating such resource as a current resource;

(B) means for determining if there is another resource upstream in the new sequence and if there is an upstream resource, selecting the upstream resource and designating such upstream resource as the current resource, and repeating step (B) until an upstream resource is not identified, then proceeding to step (C); and

(C) means for calculating a value score for the new sequence based on a composite of the assigned values of each of the resources of the new sequence selected at steps (A) and (B).

22. The system as recited in claim 20 or 21, wherein assigning a value to each resource includes a value based on at least a time score, energy score and/or human resource score for that resource.

23. The system as recited in claim 22, wherein the system is capable of calculating a value score for a sequence at any point in time during operation of that sequence.

24. The system as recited in claim 15, wherein the system is capable of calculating a value score for a sequence that processes products in batch form.

25. A computer-based system for calculating a value score for a production sequence that contains a plurality of pieces of equipment comprising:

(A) means for receiving designations for each piece of equipment as a resource type according to such piece of equipment'"'"'s function;

(B) means for selecting the last resource in the sequence and designating such resource as a current resource;

(C) means for determining if there is another resource upstream in the sequence and if there is an upstream resource, selecting the upstream resource and designating such upstream resource as the current resource, and repeating step (C) until an upstream resource is not identified, then proceeding to step (D);

(D) means for calculating a value score for the sequence based on a composite of assigned values of each of the resources selected at steps (B) and (C) that were received by the system;

(E) means for returning to a system user a calculated value score for the sequence.

26. The system as recited in claim 25, wherein the assigned value to each resource includes a value based on at least a time score, energy score and/or human resource score for that resource.

27. The system as recited in claim 25, wherein the system is capable of calculating a value score for the sequence at any point in time during operation of that sequence.

28. The system as recited in claim 25, wherein the system is capable of calculating a value score if the sequence processes products in batch form.