Method for determining the performance components of a manufacturing line

• US 6,259,959 B1
• Filed: 09/04/1998
• Issued: 07/10/2001
• Est. Priority Date: 09/04/1998
• Status: Expired due to Fees

• Current Assignee: International Business Machines Corporation
• Original Assignee: International Business Machines Corporation
• Inventors: Martin, Donald P.
• Primary Examiner(s): Grant, William
• Assistant Examiner(s): Gain, Edward F.
• Application Number:
  US09/148,826
• Time in Patent Office: 1,040 Days
• Field of Search: 700/173, 700/108, 700/109, 700/101, 700/111, 700/102, 700/100, 700/99, 705/8
• US Class Current: 700/99
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Abstract

A process for optimizing a manufacturing line comprises determining work center raw processing times of a plurality of work centers in the manufacturing line, summing the work center raw processing times to produce a manufacturing line raw processing time, determining work center cycle times of the work centers, dividing the work center cycle times by respective ones of the work center raw processing times to produce work center X-factors, weighting each of the work center X-factors by a percentage that a corresponding one of the work center raw processing times represents of the manufacturing line raw processing time to produce X-factor contributions for each of the work centers and modifying at least one work center of the work centers having an X-factor contribution higher than others of the X-factor contributions to reduce the X-factor contribution of the at least one work center.

Claims

1. A process for optimizing a manufacturing line comprising:

determining work center raw processing times of a plurality of work centers in said manufacturing line;

summing said work center raw processing times to produce a manufacturing line raw processing time;

determining work center cycle times of said work centers;

dividing said work center cycle times by respective ones of said work center raw processing times to produce work center X-factors;

weighting each of said work center X-factors by a percentage that a corresponding one of said work center raw processing times represents of said manufacturing line raw processing time to produce X-factor contributions for each of said work centers; and

modifying at least one work center of said work centers having an X-factor contribution higher than others of said X-factor contributions to reduce said X-factor contribution of said at least one work center.

2. The process in claim 1, wherein said determining work center raw processing times comprises measuring a time for a work center to perform work on a workpiece, and

said determining work center cycle times comprises measuring a time from when said workpiece arrives at said work center until said workpiece leaves said work center.

3. The process in claim 1, wherein said modifying at least one work center further comprises determining whether said at least one work center is being utilized at approximately a maximum effective capacity.

4. The process in claim 1, wherein said modifying at least one work center comprises increasing effective capacity of said at least one work center.

5. The process in claim 1, wherein said modifying at least one work center comprises optimizing batch-size for said at least one work center utilizing:

$N=1+\left(\left(X-1\right)*M*\frac{\mathrm{RPT}}{12}\right)$

wherein N comprises said batch-size, X comprises a work center X-factor of said at least one work center, M comprises an average number of workpieces processed per day by said work center, and RPT comprises a work center raw processing time of said at least one work center.

6. The process in claim 1, wherein said work center comprises a group of tools and said determining work center raw processing times, summing said work center raw processing times, determining work center cycle times, dividing said work center cycle times by respective ones of said work center raw processing times, weighting each of said work center X-factors and modifying at least one work center are repeated for each tool within said work center to determine which tool of said tools has an X-factor contribution higher than others of X-factor contributions of said tools.

7. A process for optimizing a manufacturing line comprising:

determining work center raw processing times of a plurality of work centers in said manufacturing line;

summing said work center raw processing times to produce a manufacturing line raw processing time;

determining work center cycle times of said work centers;

dividing said work center cycle times by respective ones of said work center raw processing times to produce work center X-factors; and

weighting each of said work center X-factors by a percentage that each of said work centers represents of a raw processing time of said manufacturing line to produce work center X-factor contributions for each of said work centers.

8. The process in claim 7, wherein said determining work center raw processing times comprises measuring a time for a work center to perform work on a workpiece, and

said determining work center cycle times comprises measuring a time from when said workpiece arrives at said work center until said workpiece leaves said work center.

9. The process in claim 7, wherein said work center comprises a group of tools and said determining and weighting are repeated for each tool within said work center to determine which tool of said tools has an X-factor contribution higher than others of X-factor contributions of said tools.

10. A computer system for performing a process for optimizing a manufacturing line, said computer system comprising:

a unit for determining work center raw processing times of a plurality of work centers in said manufacturing line;

a unit for summing said work center raw processing times to produce a manufacturing line raw processing time;

a unit for determining work center cycle times of said work centers;

a unit for dividing said work center cycle times by respective ones of said work center raw processing times to produce work center X-factors;

a unit for weighting each of said work center X-factors by a percentage that each of said work centers represents of a raw processing time of said manufacturing line to produce work center X-factor contributions for each of said work centers; and

a unit for modifying at least one work center of said work centers having an X-factor contribution higher than others of said X-factor contributions to reduce said X-factor contribution of said at least one work center.

11. The computer system in claim 10, wherein said unit for determining work center raw processing times comprises a unit for measuring a time for a work center to perform work on a workpiece, and

said unit for determining work center cycle times comprises a unit for measuring a time from when said workpiece arrives at said work center until said workpiece leaves said work center.

12. The computer system in claim 10, wherein said unit for modifying at least one work center further comprises a unit for determining whether said at least one work center is being utilized at approximately a maximum effective capacity.

13. The computer system in claim 10, wherein said unit for modifying at least one work center comprises a unit for increasing effective capacity of said at least one work center.

14. The computer system in claim 10, wherein said unit for modifying at least one work center comprises a unit for optimizing batch-size for said at least one work center utilizing:

$N=1+\left(\left(X-1\right)*M*\frac{\mathrm{RPT}}{12}\right)$

wherein N comprises said batch-size, X comprises a work center X-factor of said at least one work center, M comprises an average number of workpieces processed per day by said work center, and RPT comprises a work center raw processing time of said at least one work center.

15. The computer system in claim 10, wherein said work center comprises a group of tools and said unit for determining and said unit for weighting are applied to each tool within said work center to determine which tool of said tools has an X-factor contribution higher than others of X-factor contributions of said tools.

16. A computer program product comprising a program storage device readable by a computer system tangibly embodying a program of instructions executed by said computer system to perform a process for optimizing a manufacturing line, said process comprising:

determining work center raw processing times of a plurality of work centers in said manufacturing line;

summing said work center raw processing times to produce a manufacturing line raw processing time;

determining work center cycle times of said work centers;

dividing said work center cycle times by respective ones of said work center raw processing times to produce work center X-factors;

weighting each of said work center X-factors by a percentage that each of said work centers represents of a raw processing time of said manufacturing line to produce work center X-factor contributions for each of said work centers; and

modifying at least one work center of said work centers having an X-factor contribution higher than others of said X-factor contributions to reduce said X-factor contribution of said at least one work center.

17. The computer program product in claim 16, wherein said determining work center raw processing times comprises measuring a time for a work center to perform work on a workpiece, and

said determining work center cycle times comprises measuring a time from when said workpiece arrives at said work center until said workpiece leaves said work center.

18. The computer program product in claim 16, wherein said modifying at least one work center further comprises determining whether said at least one work center is being utilized at approximately a maximum effective capacity.

19. The computer program product in claim 16, wherein said modifying at least one work center comprises increasing effective capacity of said at least one work center.

20. The computer program product in claim 16, wherein said modifying at least one work center comprises optimizing batch-size for said at least one work center utilizing:

$N=1+\left(\left(X-1\right)*M*\frac{\mathrm{RPT}}{12}\right)$

wherein N comprises said batch-size, X comprises a work center X-factor of said at least one work center, M comprises an average number of workpieces processed per day by said work center, and RPT comprises a work center raw processing time of said at least one work center.

21. The computer program product in claim 16, wherein said work center comprises a group of tools and said determining and weighting repeated for each tool within said work center to determine which tool of said tools has an X-factor contribution higher than others of X-factor contributions of said tools.