Method for improving manufacturing processes

• US 5,351,195 A
• Filed: 03/12/1993
• Issued: 09/27/1994
• Est. Priority Date: 07/24/1989
• Status: Expired due to Term

• Current Assignee: Accenture Global Services Limited (Accenture PLC)
• Original Assignee: George Group Incorporated
• Inventors: Sherman, Mark A.
• Primary Examiner(s): RUGGIERO, JOSEPH F
• Application Number:
  US08/030,859
• Time in Patent Office: 564 Days
• Field of Search: 364/468, 364/478, 364/401, 364/402, 364/403, 364/191-194, 364/156, 364/149-151, 364/154
• US Class Current: 700/100
• CPC Class Codes: G05B 19/41885 characterised by modeling, simulation of the manufacturing system
• CPC Class Codes: G05B 2219/31385 Determine rate of MFL out of each process within each workstation
• CPC Class Codes: G05B 2219/31386 Determine size of batch of material for each process to meet mfl rate
• CPC Class Codes: G05B 2219/31388 Just in time JIT, kanban is box to control flow of workpiece
• CPC Class Codes: G05B 2219/32237 Repair and rework of defect, out of tolerance parts, reschedule
• CPC Class Codes: G05B 2219/32262 Work manhours, number of operators and work place
• CPC Class Codes: G05B 2219/32264 Setup time
• CPC Class Codes: G05B 2219/32265 Waiting, queue time, buffer
• CPC Class Codes: G05B 2219/32364 Simulate batch processing
• CPC Class Codes: G05B 2219/42137 Automatic tune fuzzy controller
• 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
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The batch size of materials required for each process within a workstation based on a given shipment schedule, as well as the values of several other workstation variables that are determinative of workstation and factory performance are determined. With this information, the user of the invention may schedule production for the factory or spot and prioritize workstations requiring the most improvement, and determine the character and quantity of improvement.

Claims

1. A method for improving the output capacity level of a factory, the factory having a plurality of workstations performing one or more functions, each function operating on a batch of materials, the method comprising the steps of:

inputting an output capacity level for the factory and a selected parameter for improvement;

determining whether the maximum possible variation of the selected parameter would achieve the output capacity level;

determining an achievable capacity output level when the maximum possible improvement of the parameter does not allow for the desired improved output capacity level;

determining the amount of improvement required to achieve the output capacity level when the maximum possible improvement meets or exceeds the output capacity level; and

adjusting the processes of one or more workstations of the factory to implement the parameter improvements.