Extensible model network representation system for process planning

• US 5,764,543 A
• Filed: 06/16/1995
• Issued: 06/09/1998
• Est. Priority Date: 06/16/1995
• Status: Expired due to Term

• Current Assignee: JDA Software Group Incorporated (RedPrairie Holding Incorporated)
• Original Assignee: i2 Technologies Incorporated (Panasonic Holdings Corporation)
• Inventors: Kennedy, Brian M.
• Primary Examiner(s): Trans, Vincent N.
• Application Number:
  US08/491,153
• Time in Patent Office: 1,089 Days
• Field of Search: 364/578, 364/468.01, 364/468.03, 364/468.05, 364/468.09, 364/468.1, 705/7, 705/8, 705/22, 705/28, 705/29
• US Class Current: 703/2
• 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

A computer software system for modeling a process capability on a computer is provided. The computer software system comprises an operation model type for defining a plurality of operation models (33, 36, 44, 52 and 57). Each operation model represents an activity that can be performed by a process. A resource model type is for defining a plurality of resource models (32, 38, 40, 46, 48, 54, 56 and 58). Each resource model represents capacity available for use in performing an activity and rules for allocating capacity to the activity. A buffer model type is for defining a plurality of buffer models (34, 42, 50, and 60). Each buffer model represents rules for controlling a flow of material between activities. The operation model type, buffer model type, and resource model type each comprise a plurality of fields defining attributes that include a plurality of extension selector fields. Defined operation models, buffer models, and resource models are stored as nodes in an interrelated process network model.

Claims

1. A computer system for modeling a process capability for use in process planning on the computer system, the computer system comprising:

a plurality of operation models defined from an operation model type and stored by the computer system, each operation model representing an activity that can be performed by a process;

a plurality of resource models defined from a resource model type and stored by the computer system, each resource model representing capacity available for use in performing an activity and rules for allocating capacity to the activity, the activity represented by an operation model; and

a plurality of buffer models defined from a buffer model type and stored by the computer system, each buffer model representing rules for controlling a flow of material between activities, the activities represented operation models;

the operation model type, buffer model type, and resource model type each having a plurality of fields defining attributes, the plurality of fields including a plurality of extension selector fields that allow a user to specify one of a plurality of optional extensions incorporating additional fields and semantics in addition to fields specified by the model type into each model selecting the optional extension; and

a process network model, stored by the computer system, interrelating the operation models, the buffer models, and the resource models as nodes;

the process network model formed by the plurality of operation models each specifying buffer models from which material is consumed and buffer models to which material is supplied and specifying resource models having capacity used in performing the activity specified by the operation model;

such that both material and capacity usage are simultaneously represented by the process network model along with timing constraints between activities.

2. The computer system of claim 1, wherein the operation model type has associated with one of the extension selectors a plurality of extensions that define behavior as a sequence of other operations, with varying rules on how the sequence may be ordered or may spread out in time.

3. The computer system of claim 1, wherein the operation model type has associated with one of the extension selectors a plurality of extensions that define behavior as one of several other operation models, with varying rules on how a single one of those operation models is chosen to be performed.

4. The computer system of claim 1, wherein the operation model type has associated with one of the extension selectors a plurality of extensions that define behavior as a set of other operations each having individual precedence constraints, with varying rules on how the set of operations is planned.

5. The computer system of claim 1, wherein the operation model type includes a plurality of extensions that define behavior as a sequence of other operations, as one of several other operation models, and as a set of other operations each having individual precedence constraints, such that a complex hierarchy of operation models can be formed in order to represent complex processes with alternatives, sequences, and precedence constraints.

6. The computer system of claim 1, wherein the resource model type has associated with one of the extension selectors a plurality of extensions defining fields and semantics that each describe how an efficiency of the resource model changes over time.

7. The computer system of claim 1, wherein the resource model type has associated with one of the extension selectors a plurality of extensions defining fields and semantics that each describe a maximum size of operation models that simultaneously use a resource model.

8. The computer system of claim 1 wherein the resource model type has associated with one of the extension selectors a plurality of extensions that define fields and semantics that each describe when maintenance operations should be planned.

9. The computer system of claim 1, wherein the resource model type has associated with one of the extension selectors a plurality of extensions defining fields and semantics that each describe how operation plans should be padded to compensate for variability of a resource model.

10. The computer system of claim 1, wherein:

the resource model type has associated with one of the extension selectors a plurality of extensions defining fields and semantics that each describe how an efficiency of the resource model changes over time, describe a maximum size of operation models that simultaneously use a resource model, describe when maintenance operations should be planned, and describe how operation plans should be padded to compensate for variability of a resource model;

such that a wide variety of resource models can be represented in one network without greatly increasing complexity of each resource model requiring only a small subset of the overall software system modeling capabilities.

11. The computer system of claim 1, wherein the buffer model type has an operation that defines how material managed by a buffer is stored, and the specified operation model can be extended to specify different scrap factors.

12. The computer system of claim 1, wherein the buffer model type has an operation that defines how material is received into a buffer and how the material is picked from the buffer.

13. The computer system of claim 1, further comprising:

a plurality of operation-plan models defined from an operation-plan model type and stored by the computer system, each operation-plan model representing a planned activity to be performed during a particular period in order to achieve a particular purpose;

a plurality of resource-plan models defined from a resource-plan model type and stored by the computer system, each resource-plan model representing an amount of available capacity and planned usage of the available capacity by operation-plan models; and

a plurality of buffer-plan models defined from a buffer-plan model type and stored by the computer system, each buffer-plan model representing planned flow of material that controlled by the buffer-plan model as a result of planned operation-plan models;

the operation-plan model types, buffer-plan model types, and resource-plan model types each having a plurality of fields that define attributes, including a plurality of extension selector fields corresponding to operation, buffer, and resource model type fields and specifying corresponding extension of a plurality of optional extensions which incorporate additional fields and semantics into each model selecting the optional extension in addition to those specified by the model type; and

a process-plan network model, stored by the computer system, interrelating the defined operation models, the buffer models, and the resource models as nodes;

the process-plan network model formed by operation-plan models specifying buffer-plan models from which material is consumed and buffer-plan models to which material is supplied and specifying resource-plan models having capacity planned to be used in order to perform the activity specified by the operation-plan model;

such that both material and capacity usage are simultaneously represented and addressed along with operation timing constraints in creating and managing a plan for the process.

14. The computer system of claim 13, wherein:

the operation model type has associated with one of the extension selectors a plurality of extensions that define behavior as a sequence of other operations, with varying rules on how the sequence may be ordered or may spread out in time; and

the operation-plan model type has a plurality of extensions each corresponding to each of the extensions of the operation model type, which represent extension-specific choices for a particular plan for the process.

15. The computer system of claim 13, wherein:

the operation model type has associated with one of the extension selectors a plurality of extensions that define behavior as one of several other operation models, with varying rules on how a single one of those operation models is chosen to be performed; and

the operation-plan model type has a plurality of extensions each corresponding to each of the extensions of the operation model type, which represent extension-specific choices for a particular plan for the process.

16. The computer system of claim 13, wherein:

the operation model type has associated with one of the extension selectors a plurality of extensions that define behavior as a set of other operations each having individual precedence constraints, with varying rules on how the set of operations is planned; and

the operation-plan model type has a plurality of extensions each corresponding to each of the extensions of the operation model type, which represent extension-specific choices for a particular plan for the process.

17. The computer system of claim 13, wherein:

the operation model type includes a plurality of extensions that define behavior as a sequence of other operations, as one of several other operation models, and as a set of other operations each having individual precedence constraints, such that a complex hierarchy of operation models can be formed in order to represent complex processes with alternatives, sequences, and precedence constraints;

the operation-plan model type has a plurality of extensions each corresponding to each of the extensions of the operation model type, which represent extension-specific choices for a particular plan for the process; and

a plan for a complex process can be represented with all decisions to be made in order to define a particular plan.

18. The computer system of claim 13, wherein:

the resource model type has associated with one of the extension selectors a plurality of extensions defining fields and semantic that each describe how an efficiency of the resource model changes over time; and

the resource-plan model type has a plurality of extensions each corresponding to each of the extensions of the resource model type, which represent extension-specific choices for a particular plan for the process.

19. The computer system of claim 13, wherein:

the resource model type has associated with one of the extension selectors a plurality of extensions defining fields and semantics that each describe a maximum size of operation models that simultaneously use a resource model; and

the resource-plan model type has a plurality of extensions corresponding to each of the extensions of the resource model type, which represent extension-specific choices for a particular plan for the process.

20. The computer system of claim 13, wherein:

the resource model type has associated with one of the extension selectors a plurality of extensions that define fields and semantics that each describe when maintenance operations should be planned; and

the resource-plan model type has a plurality of extensions corresponding to each of the extensions of the resource model type, which represent extension-specific choices for a particular plan for the process.

21. The computer system of claim 13, wherein:

the resource model type has associated with one of the extension selectors a plurality of extensions defining fields and semantics that each describe how operation plans should be padded to compensate for variability of a resource model; and

the resource-plan model type has a plurality of extensions corresponding to each of the extensions of the resource model type, which represent extension-specific choices for a particular plan for the process.

22. The computer system of claim 13, wherein:

the resource model type has associated with one of the extension selectors a plurality of extensions defining fields and semantics that each describe how an efficiency of the resource model changes over time, describe a maximum size of operation models that simultaneously use a resource model, describe when maintenance operations should be planned, and describe how operation plans should be padded to compensate for variability of a resource model; and

the resource-plan model type has a plurality of extensions each corresponding to each of the extensions of the resource model type, which represent extension-specific choices for a particular plan for the process;

such that a wide variety of resource models and a plan for each of the resource models containing all decisions regarding capacity can be represented in one network without greatly increasing complexity of each resource model requiring only a small subset of the overall software system modeling capabilities.

23. The computer system of claim 13, wherein the buffer model type has an operation that defines how material managed by a buffer is stored, and the buffer-plan models create operation-plan models to store the material managed by the buffer.

24. The computer system of claim 13, wherein:

the buffer model type has an operation that defines how material is received into a buffer and how material is picked from the buffer; and

the buffer-plan models create operation-plan models to receive each lot of material and pick each lot consumed.

25. The computer system of claim 13, wherein:

the buffer model type has an operation that defines how material managed by a buffer is stored, and the specified operation model can be extended to specify different scrap factors and has an operation that defines how material is received into a buffer and how the material is picked from the buffer; and

the buffer-plan models create operation-plan models to receive each lot of material and pick each lot consumed and to store the material that is managed by the buffer at all times;

such that a wide variety of resource models and a plan for each of those resource models containing all decisions regarding capacity can be represented in one network without greatly increasing complexity of each resource model requiring only a small subset of the overall software system modeling capabilities; and

such that a complex hierarchy of operation models can be formed to represent complex processes with many alternatives, sequences, precedence constraints, and a plan for such a complex process can be represented with all the decisions to be made in order to define a particular plan.

26. The computer system of claim 25, used to model and plan a manufacturing process wherein:

operation models are used to represent traditional manufacturing operations, routings, bills-of-material, and storage;

resource models are used to represent machines, tools, fixtures, and labor; and

buffer models are used to represent SKUS, bins, buffers, or inventories; and

operation-plans, resource-plans and buffer-plans are used to represent corresponding plans for those entities.

27. The computer system of claim 25, used to model a distribution network wherein:

operation models are used to represent transport, loading, unloading, storage, receiving, picking, palletizing, and packaging activities and traditional bills-of-distribution;

resource models represent docks, trucks, pallets, forklifts, labor, and storage facilities; and

buffer models represent SKUS, bins, and inventories; and

operation-plans, resource-plans, and buffer-plans are used to represent corresponding plans for those entities.

28. The computer system of claim 25, used to model and plan a manufacturing process wherein:

operation models are used to represent traditional manufacturing operations, routings, bills-of-material, and storage;

resource models are used to represent machines, tools, fixtures, and labor; and

buffer models are used to represent SKUS, bins, buffers, or inventories;

operation models are used to represent transport, loading, unloading, storage, receiving, picking, palletizing, and packaging activities and traditional bills-of-distribution;

resource models represent docks, trucks, pallets, forklifts, labor, and storage facilities; and

buffer models represent SKUS, bins, and inventories; and

operation-plans, resource-plans and buffer-plans are used to represent corresponding plans for those entities;

such that a full supply chain can be modeled and planned.

29. The computer system of claim 25 used to model project plans wherein:

operation models are used to represent requirements gathering, design, testing, prototyping, tooling, and production;

resource models are used to represent the labor, machines, tools, and testers; and

buffer models represent various milestones to be achieved in order to move from one activity to another; and

operation-plans, resource-plans, and buffer-plans are used to represent corresponding plans for those entities.

30. The computer system of claim 25, used to model and plan a manufacturing process wherein:

operation models are used to represent traditional manufacturing operations, routings, bills-of-material, and storage;

resource models are used to represent machines, tools, fixtures, and labor; and

buffer models are used to represent SKUS, bins, buffers, or inventories;

operation models are used to represent transport, loading, unloading, storage, receiving, picking, palletizing, and packaging activities and traditional bills-of-distribution;

resource models represent docks, trucks, pallets, forklifts, labor, and storage facilities; and

buffer models represent SKUS, bins, and inventories; and

operation models are used to represent requirements gathering, design, testing, prototyping, tooling, and production;

resource models are used to represent the labor, machines, tools, and testers; and

buffer models represent various milestones to be achieved in order to move from one activity to another; and

operation-plans, resource-plans, and buffer-plans are used to represent corresponding plans for those entities;

such that a full supply chain can be modeled and planned and such that a supply chain and design activities involved in introducing new products and phasing out old products together with on-going production and delivery of existing products can be represented and planned.

31. The computer system of claim 1, wherein:

the buffer model type has an operation that defines how material managed by a buffer is stored, and the specified operation model can be extended to specify different scrap factors and has an operation that defines how material is received into a buffer and how the material is picked from the buffer;

such that a wide variety of resource models can be represented in one network without greatly increasing complexity of each resource model requiring only a small subset of the overall software system modeling capabilities; and

such that a complex hierarchy of operation models can be formed to represent complex processes with many alternatives, sequences, precedence constraints.

32. The computer system of claim 31, used to model a manufacturing process wherein:

operation models are used to represent traditional manufacturing operations, routings, bills-of-material, and storage;

resource models are used to represent machines, tools, fixtures, and labor; and

buffer models are used to represent SKUS, bins, buffers;

or inventories.

33. The computer system of claim 31, used to model a distribution network wherein:

operation models are used to represent transport, loading, unloading, storage, receiving, picking, palletizing, and packaging activities and traditional bills-of-distribution;

resource models represent docks, trucks, pallets, forklifts, labor, and storage facilities;

buffer models represent SKUS, bins, and inventories.

34. The computer system of claim 31, used to model a manufacturing process wherein:

operation models are used to represent traditional manufacturing operations, routings, bills-of-material, and storage;

resource models are used to represent machines, tools, fixtures, and labor; and

buffer models are used to represent SKUS, bins, buffers, or inventories; and

operation models are used to represent transport, loading, unloading, storage, receiving, picking, palletizing, and packaging activities and traditional bills-of-distribution;

resource models represent docks, trucks, pallets, forklifts, labor, and storage facilities;

buffer models represent SKUS, bins, and inventories;

such that a full supply chain can be modeled.

35. The computer system of claim 31 used to model project plans wherein:

operation models are used to represent requirements gathering, design, testing, prototyping, tooling, and production;

resource models are used to represent the labor, machines, tools, and testers; and

buffer models represent various milestones to be achieved in order to move from one activity to another.

36. The computer system of claim 31, used to model a manufacturing process wherein:

operation models are used to represent traditional manufacturing operations, routings, bills-of-material, and storage;

resource models are used to represent machines, tools, fixtures, and labor; and

buffer models are used to represent SKUS, bins, buffers, or inventories;

operation models are used to represent transport, loading, unloading, storage, receiving, picking, palletizing, and packaging activities and traditional bills-of-distribution;

resource models represent docks, trucks, pallets, forklifts, labor, and storage facilities;

buffer models represent SKUS, bins, and inventories; and

operation models are used to represent requirements gathering, design, testing, prototyping, tooling, and production;

resource models are used to represent the labor, machines, tools, and testers; and

buffer models represent various milestones to be achieved in order to move from one activity to another;

such that a full supply chain can be modeled and a supply chain and design activities involved in introducing new products and phasing out old products together with on-going production and delivery of existing products can be represented.

37. The computer system of claim 1, wherein each operation model may specify another operation, each resource model may specify another resource, and each buffer model may specify another buffer as its family and may specify a number of fields as inherited from that family, thereby allowing the fields to be changed in the family by a user, and result in changes to all models that inherit that field.

38. The computer system of claim 37, wherein each operation model, resource model, and buffer model that specifies a family can also specify a range of dates during which the model is effective such that outside of the range the model is modeled as if the model does not exist.

39. A computer system for executing computer software for modeling a process capability, the computer system comprising:

a data storage device operable to store data relating to a model of process capability;

an execution memory operable to store data representing computer software; and

a processor coupled to the data storage device and to the execution memory, the processor operable to execute the computer software, wherein the computer software system comprises;

a plurality of operation models defined from an operation model type, each operation model representing an activity that can be performed by a process;

a plurality of resource models defined from a resource model type, each resource model representing capacity available for use in performing an activity and rules for allocating capacity to the activity; and

a plurality of buffer models defined from a buffer model type, each buffer model representing rules for controlling a flow of material between activities;

the operation model type, buffer model type, and resource model type each having a plurality of fields defining attributes, the plurality of fields including a plurality of extension selector fields that allow a user to specify one of a plurality of optional extensions incorporating additional fields and semantics in addition to fields specified by the model type into each model selecting the optional extension; and

a process network model, interrelating the operation models, the buffer models, and the resource models as nodes;

the process network model formed by a plurality of operation models each specifying buffer models from which material is consumed and buffer models to which material is supplied and specifying resource models having capacity used in performing the activity specified by the operation model;

such that both material and capacity usage are simultaneously represented by the process network model along with timing constraints between activities.

40. The computer system of claim 39, wherein the computer software further comprises:

a plurality of operation-plan models defined from an operation-plan model type, each operation-plan model representing a planned activity to be performed during a particular period in order to achieve a particular purpose;

a plurality of resource-plan models defined from a resource-plan model type, each resource-plan model representing an amount of available capacity and planned usage of the available capacity by operation-plan models; and

a plurality of buffer-plan models defined from a buffer-plan model type, each buffer-plan model representing planned flow of material that controlled by the buffer-plan model as a result of planned operation-plan models;

the operation-plan model types, buffer-plan model types, and resource-plan model types each having a plurality of fields that define attributes, including a plurality of extension selector fields corresponding to operation, buffer, and resource model type fields and specifying corresponding extension of a plurality of optional extensions which incorporate additional fields and semantics into each model selecting the optional extension in addition to those specified by the model type; and

a process-plan network model interrelating the operation models, the buffer models, and the resource models as nodes , the process-plan network model formed by operation-plan models specifying buffer-plan models from which material is consumed and buffer-plan models to which material is supplied and specifying resource-plan models having capacity planned to be used in order to perform the activity specified by the operation-plan model;

such that both material and capacity usage are simultaneously represented by the process-plan network model and addressed along with operation timing constraints in creating and managing a plan for the process.