Parallel manufacturing system

• US 5,285,392 A
• Filed: 11/27/1991
• Issued: 02/08/1994
• Est. Priority Date: 11/27/1991
• Status: Expired due to Fees

• Current Assignee: Mckinsey & Company Incorporated
• Original Assignee: Mckinsey & Company Incorporated
• Inventors: Bernstein, Alan, Kyle, Donald W., Ammon, Karen E.
• Primary Examiner(s): Smith, Jerry
• Assistant Examiner(s): Garland, Steven R.
• Application Number:
  US07/799,362
• Time in Patent Office: 804 Days
• Field of Search: 364/131, 364/133, 364/134, 364/401-403, 364/468-473, 364/DIG. 1, 364/DIG. 2
• US Class Current: 700/100
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32263 Afo products, their components to be manufactured, lot selective
• CPC Class Codes: G05B 2219/32289 Determine number of components, start of their production, allocate processor
• CPC Class Codes: G05B 2219/33081 Parallel computing, pipeline
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A parallel manufacturing system for use in a manufacturing plant that utilizes a massively parallel computer determines the scheduling of all manufacturing operations used in connection with the manufacture of the products made in the plant. The system utilizes an explosion procedure to determine the net requirements for all components used in the manufacturing operations, and then schedules any manufacturing operations necessary to make the required components.

Claims

1. A parallel manufacturing system for use in connection with a manufacturing plant, said manufacturing system comprising:

memory means for storing manufacturing data representing the relationship between at least one product and a number of components necessary for the manufacture of said product, each of a plurality of said components being produced by a respective manufacturing operation;

parallel processing means coupled to said memory means, said parallel processing means having at least 100 processors capable of substantially simultaneous parallel operation, said parallel processing means comprising;

means for determining the number of each of said components that must be manufactured to produce a quantity of said product; and

means for determining when each of said manufacturing operations should begin; and

means coupled to said memory means for assigning said manufacturing data stored in said memory means among said processors in said parallel processing means.

2. A parallel manufacturing system as defined in claim 1 wherein said parallel processing means includes at least 1,000 processors capable of parallel operation.

3. A parallel manufacturing system as defined in claim 1 wherein said for determining the number of each of said components that must be manufactured to produce said quantity of said product comprises:

means for determining whether a quantity on hand for each of said components exceeds a demand quantity for each of said components.

4. A parallel manufacturing system as defined in claim 1 wherein said quantity of said product is the difference between a quantity of said product in inventory and a quantity of said product for which orders have been received.

5. A parallel manufacturing system as defined in claim 1 wherein said means for determining when said manufacturing operations should begin determines the date on which each of said manufacturing operations should begin.

6. A parallel manufacturing system as defined in claim 5 wherein said means for determining when said manufacturing operations should begin determines the time at which each of said manufacturing operations should begin.

7. A parallel manufacturing system as defined in claim 1 wherein said manufacturing data comprises data representing a relational tree for each of a plurality of products made by the manufacturing plant.

8. A parallel manufacturing system as defined in claim 7 wherein each of said relational trees includes data representing the relationship between a product, all manufacturing operations necessary for the manufacture of said product, and all components necessary for the manufacture of said product.

9. A parallel manufacturing system as defined in claim 7 wherein said means for assigning said manufacturing data among said parallel processors assigns the data representing each of said relational trees to a plurality of said parallel processors.

10. A parallel manufacturing system comprising:

a memory that stores manufacturing data representing the relationship between at least one product and a number of components necessary for the manufacture of said product, each of a plurality of said components being produced by a respective manufacturing operation;

a parallel computer coupled to said memory, said parallel computer having at least 100 processors capable of parallel operation, said parallel computer determining the number of each of said components that must be manufactured to produce a quantity of said product and determining when each of said manufacturing operations should begin; and

an assignment module that assigns said manufacturing data stored in said memory among said processors in said parallel computer.

11. A parallel manufacturing system as defined in claim 10 wherein said parallel computer comprises at least 1,000 parallel processors.

12. A parallel manufacturing system as defined in claim 11 wherein said assignment module comprises a computer program routine stored in said parallel computer.

13. A parallel manufacturing system as defined in claim 12 wherein said quantity of said product is the difference between a quantity of said product in inventory and a quantity of said product for which orders have been received.

14. A parallel manufacturing system as defined in claim 12 wherein said manufacturing data representing the relationship between said product and said components comprises operation data relating to the manufacturing operations that are performed in the manufacture of said product.

15. A parallel manufacturing system as defined in claim 14 wherein said operation data includes operation data records, each of which corresponds to a respective manufacturing operation necessary for the manufacture of said product.

16. A method for use in a manufacturing plant, said method comprising the steps of:

(a) generating manufacturing data representing the relationship between a product and number of components used in the manufacture of said product;

(b) distributing said manufacturing data generated in said step (a) among a plurality of parallel processors in a massively parallel computer; and

(c) using said manufacturing data to determine the number of said components that must be manufactured to produce a quantity of said product.

17. A method as defined in claim 16 wherein each of said steps (a)-(c) is performed substantially simultaneously by each of said parallel processors in said massively parallel computer system.

18. A method for use in a manufacturing plant, said method of comprising the steps of:

(a) generating manufacturing data relating to the relationship between a product and a number of components used in the manufacture of said product;

(b) generating demand data relating to a quantity of said product that is needed;

(c) generating supply data relating to a quantity of said product that is on hand;

(d) distributing said manufacturing data, said demand data and said supply data generated in said steps (a)-(c) among a plurality of parallel processors in a massively parallel computer; and

(e) determining a quantity of components needed to manufacture said quantity of said product by comparing said demand data generated in said step (b) with said supply data generated in said step (c).

19. A method as defined in claim 18 wherein said manufacturing data includes operation data for each manufacturing operation used in the manufacture of said product.

20. A method as defined in claim 19 wherein said operations data includes component data relating to any components that are used in the operation corresponding to said operation data.

21. A method as defined in claim 18 additionally comprising the step of:

(f) automatically generating demand data relating to a quantity of at least one component used in the manufacture of said product when said quantity of said product that is needed as reflected by said demand data exceeds said quantity of said product that is on hand as reflected by said supply data.

22. A method as defined in claim 18 wherein said manufacturing data represents a relational tree for said product, said relational tree having a plurality of tree levels including a highest level, a lowest level, and at least one intermediate level, and wherein said step (e) comprises the steps of:

(f) beginning with said highest level in said relational tree, determining a number of components required in said highest level by comparing demand data for said highest-level components with supply data for said highest-level components;

(g) for an intermediate level in said relation tree, determining a number of components required in said intermediate level by comparing demand data for said intermediate-level components with supply data for said intermediate-level components; and

(h) repeating said step (g) until a number of components required in said lowest level in said tree has been determined.

23. A method as defined in claim 22 additionally comprising the step of:

(i) automatically generating demand data when a needed quantity of a component corresponding to one of said levels as reflected by said demand data exceeds a quantity of hand of said component of said one of said levels as reflected by said supply data.

24. A method for use in a manufacturing plant, said method comprising the steps of:

(a) generating manufacturing data representing the relationship between a product and a number of components used in the manufacture of said product;

(b) distributing said manufacturing data generated in said step (a) among a plurality of parallel processors in a massively parallel computer;

(c) using said manufacturing data to determine a number of said components that must be manufactured to produce a quantity of said product;

(d) generating a visual display relating to said number of said components that must be manufactured as determined in said step (c);

(e) modifying said manufacturing data in response said visual display generating is said step (d); and

(f) repeating said steps (c)-(e) with said modified manufacturing data until a satisfactory manufacturing plan is achieved.

25. A method as defined in claim 24 additionally comprising the step of (g) saving said satisfactory manufacturing plan to a memory after the final repetition of said step (f).

26. A method for use in a manufacturing plant, said method comprising the steps of:

(a) generating manufacturing data representing the relationship between a product and a number of components used in the manufacture of said product;

(b) distributing said manufacturing data generated in said step (a) among a plurality of parallel processors in a massively parallel computer; and

(c) using said manufacturing data to determine when all manufacturing operations that produce any components that must be manufactured to produce a quantity of said product should be performed.

27. A method as defined in claim 26 wherein the dates on which all manufacturing operations should be performed during said step (c) are specified.

28. A method as defined in claim 26 wherein said manufacturing data comprises a plurality of operation data records, each of which relates to an operation that is performed in the manufacture of said product, each said operation data record including:

1) an identification number for said operation; and

2) an identification number for each operation that produces a component that is used in said operation.

29. A method as defined in claim 28 wherein said manufacturing data that relates to components used in the manufacturing of said product comprises data relating to the operations that produce said components.

30. A method of processing as defined in claim 26 wherein said manufacturing data is distributed among said parallel processors during said step (b) in accordance with a mapping table.

31. A method of processing data as defined in claim 30 wherein said mapping table is distributed among said parallel processors.

32. A method for use in the manufacture of at least one product in a manufacturing plant, comprising the steps of:

(a) generating manufacturing data representing a number of manufacturing operations necessary in the manufacture of said product, said operations generating a number of components, said step (a) comprising the steps of;

(a1) determining said manufacturing operations that are necessary in the manufacture of said product;

(a2) determining said components that are generated by said operations of said step (a1);

(a3) determining a number of manufacturing operations in which said components of said step (a2) are needed;

(a4) generating said manufacturing data to represent the relationship between said operations of said step (a1) and said operations of said step (a3);

(b) assigning said manufacturing data generating during said step () to a plurality of parallel processors; and

(c) determining a time schedule for said operations of said step (a1) utilizing said parallel processors.

33. A method as defined in claim 32 wherein said manufacturing data is assigned to at least 100 parallel processors during said step (b).

34. A method as defined in claim 32 wherein said manufacturing data is assigned to at least 1,000 parallel processors during said step (b).