Systems and methods for manufacturing a product in a pull and push manufacturing system and associated methods and computer program products for modeling the same
First Claim
1. A method of modeling the manufacturing of a product in a pull and push manufacturing system, where the product comprises at least one model and each model includes at least one component, said method comprising:
- simulating operation of the manufacturing system, wherein simulating comprises;
generating a master firing order schedule (MFOS) for a plurality of orders for at least one model of the product over a defined time period, wherein the orders are in a predefined sequence and each order includes a defined release time;
generating a component firing order schedule (CFOS) for a plurality of components corresponding to the models ordered in the MFOS, wherein the components are in a predetermined sequence and each component has a defined release time, the predetermined sequence being set based upon the defined release times of the respective orders and manufacturing times associated with the components such that at least one component for an order is capable of being released after at least one component for a subsequent order;
releasing each order in the MFOS at a respective release time and releasing each component in the CFOS at a respective release time;
producing the components at a set number of production centers for the respective set manufacturing times, wherein when a subsequent component is released before all preceding components in the CFOS are produced the subsequent component is buffered until the preceding components are produced; and
assembling the orders from the produced components at a set number of assembly lines for set assembly times associated with the models ordered, wherein when a subsequent order is released before the models in all preceding orders in the MFOS are assembled the subsequent order is buffered until the models in all preceding orders are assembled; and
adjusting at least one of the set assembly time for at least one of the models of the product, the set manufacturing time for at least one of the components of the models, the set number of production centers or the set number of assembly lines based upon at least one of a subsequent component or a subsequent order being buffered.
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Accused Products
Abstract
A system of manufacturing a product in a pull and push manufacturing system is provided, where the product comprises at least one model and each model includes at least one component. The system includes an order scheduler, a component scheduler, a make-to-order (MTO) portion and an assemble to order (ATO) portion. The order scheduler is capable of receiving order(s) for model(s) of the product, and the component scheduler is capable of generating a component firing order schedule (CFOS) for the components corresponding to the models ordered. The MTO portion can release each component and thereafter produce the components. And the ATO portion can release each order and thereafter assemble the orders released from the produced components at a number of assembly lines. Advantageously, a number of system parameters can be determined based upon modeling the manufacturing system.
26 Citations
30 Claims
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1. A method of modeling the manufacturing of a product in a pull and push manufacturing system, where the product comprises at least one model and each model includes at least one component, said method comprising:
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simulating operation of the manufacturing system, wherein simulating comprises; generating a master firing order schedule (MFOS) for a plurality of orders for at least one model of the product over a defined time period, wherein the orders are in a predefined sequence and each order includes a defined release time; generating a component firing order schedule (CFOS) for a plurality of components corresponding to the models ordered in the MFOS, wherein the components are in a predetermined sequence and each component has a defined release time, the predetermined sequence being set based upon the defined release times of the respective orders and manufacturing times associated with the components such that at least one component for an order is capable of being released after at least one component for a subsequent order; releasing each order in the MFOS at a respective release time and releasing each component in the CFOS at a respective release time; producing the components at a set number of production centers for the respective set manufacturing times, wherein when a subsequent component is released before all preceding components in the CFOS are produced the subsequent component is buffered until the preceding components are produced; and assembling the orders from the produced components at a set number of assembly lines for set assembly times associated with the models ordered, wherein when a subsequent order is released before the models in all preceding orders in the MFOS are assembled the subsequent order is buffered until the models in all preceding orders are assembled; and adjusting at least one of the set assembly time for at least one of the models of the product, the set manufacturing time for at least one of the components of the models, the set number of production centers or the set number of assembly lines based upon at least one of a subsequent component or a subsequent order being buffered. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of manufacturing a product in a pull and push manufacturing system, where the product comprises at least one model and each model includes at least one component, said method comprising:
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receiving a plurality of orders for at least one model of the product, wherein each model has an associated assembly time, and wherein the orders are in a predefined sequence and each order includes a defined release time; generating a component firing order schedule (CFOS) for a plurality of components corresponding to the models ordered, wherein the components are in a predetermined sequence and each component has a defined release time, the predetermined sequence being set based upon the defined release times of the respective orders and manufacturing times associated with the components such that at least one component for an order is capable of being released after at least one component for a subsequent order; releasing each order at a respective release time and releasing each component in the CFOS at a respective release time; producing the components released at a number of production centers and thereafter assembling the orders released from the produced components at a number of assembly lines, wherein at least one of the assembly times of the models ordered, the manufacturing times of the components of the models ordered, the number of production centers or the number of assembly lines are set; determining when at least one of a subsequent component or a subsequent order is buffered, wherein determining when a subsequent component is buffered comprises determining when a subsequent component is released before all preceding components in the CFOS are produced, and wherein determining when a subsequent order is buffered comprises determining when a subsequent order is released before the models in all preceding orders received are assembled; and adjusting at least one of the set assembly time for at least one of the models of the product, the set manufacturing time for at least one of the components of the models, the set number of production centers or the set number of assembly lines based upon at least one of a subsequent component or a subsequent order being buffered. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15)
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16. A system of manufacturing a product in a pull and push manufacturing system, where the product comprises at least one model and each model includes at least one component, said system comprising:
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an order scheduler capable of receiving a plurality of orders for at least one model of the product, wherein each model has an associated assembly time, and wherein the orders are in a predefined sequence and each order includes a defined release time; a component scheduler capable of generating a component firing order schedule (CFOS) for a plurality of components corresponding to the models ordered, wherein the components are in a predetermined sequence and each component has a defined release time, the predetermined sequence being set based upon the defined release times of the respective orders and manufacturing times associated with the components such that at least one component for an order is capable of being released after at least one component for a subsequent order; a make-to-order (MTO) portion capable of releasing each component in the CFOS at a respective release time and thereafter producing the components released at a number of production centers; an assemble-to-order (ATO) portion capable of releasing each order at a respective release time and thereafter assembling the orders released from the produced components at a number of assembly lines, wherein at least one of the assembly times of the models ordered, the manufacturing times of the components of the models ordered, the number of production centers or the number of assembly lines are set; and a processing element capable of determining when at least one of a subsequent component or a subsequent order is buffered, wherein said processing element is capable of adjusting at least one of the set assembly time for at least one of the models of the product, the set manufacturing time for at least one of the components of the models, the set number of production centers or the set number of assembly lines based upon at least one of a subsequent component or a subsequent order being buffered. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23)
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24. A computer program product for modeling the manufacturing of a product in a pull and push manufacturing system, where the product comprises at least one model and each model includes at least one component, said computer program product comprising a computer-readable storage medium having computer-readable program code portions stored therein, the computer-readable program portions comprising:
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a first executable portion for simulating operation of the manufacturing system, wherein said first executable portion simulates the operation by; generating a master firing order schedule (MFOS) for a plurality of orders for models of the product over a defined time period, wherein the orders are in a predefined sequence and each order includes a defined release time; generating a component firing order schedule (CFOS) for a plurality of components corresponding to the models ordered in the MFOS, wherein the components are in a predetermined sequence and each component has a defined release time, the predetermined sequence being set based upon the defined release times of the respective orders and manufacturing times associated with the components such that at least one component for an order is capable of being released after at least one component for a subsequent order; releasing each order in the MFOS at a respective release time and releasing each component in the CFOS at a respective release time; producing the components at a set number of production centers for the respective set manufacturing times, wherein when a subsequent component is released before all preceding components in the CFOS are produced the subsequent component is buffered until the preceding components are produced; and assembling the orders from the produced components at a set number of assembly lines for set assembly times associated with the models ordered, wherein when a subsequent order is released before the models in all preceding orders in the MFOS are assembled the subsequent order is buffered until the models in all preceding orders are assembled; and a second executable portion for adjusting at least one of the set assembly time for at least one of the models of the product, the set manufacturing time for at least one of the components of the models, the set number of production centers or the set number of assembly lines based upon at least one of a subsequent component or a subsequent order being buffered. - View Dependent Claims (25, 26, 27, 28, 29, 30)
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Specification