System and method for dynamically simulating value stream and network maps

• US 7,599,755 B2
• Filed: 12/05/2005
• Issued: 10/06/2009
• Est. Priority Date: 09/12/2005
• Status: Active Grant

• Current Assignee: Createasoft Incorporated
• Original Assignee: Hosni Adra
• Inventors: Adra, Hosni (I)
• Primary Examiner(s): Hartman, Jr.; Ronald D
• Application Number:
  US11/294,989
• Publication Number:
  US 20070073421A1
• Time in Patent Office: 1,401 Days
• Field of Search: 700/49, 700/51, 700/99, 700/100, 700/103, 700/108, 700/109, 703/2, 702/81, 702/84, 702/182
• US Class Current: 700/108
• CPC Class Codes: G05B 13/041 in which a variable is automatically adjusted to optimise the performance
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: G06F 13/10 Program control for peripheral devices G06F13/14 - G06F13/42 take precedence

Abstract

A computer readable medium comprising instructions which when executed by a computer system causes the computer to implement a method for creating a dynamic value network map of a process flow is provided. For a plurality of processed objects, the method identifies corresponding value stream metrics and triggers a state engine to simulate the process flow. The state engine is configured to manage all operations rules related to the value network map. The method dynamically updates the value stream metrics during the simulation of the value network map.

Claims

1. A computer readable medium storing instructions executed by a computer system to implement a method for creating a dynamic value stream map of a process flow, the process flow characterized by a plurality of objects interacting with a plurality of cells, which are each characterized by a corresponding plurality of productivity parameters, the method comprising:

establishing a plurality of value stream metrics, the plurality of value stream metrics being elements of the value stream map and productivity indicators corresponding to at least one of the plurality of objects, the plurality of cells and interrelationships between the plurality of objects and the plurality of cells;

triggering a state engine to simulate the value stream map, the state engine configured to manage the plurality of value stream metrics, the plurality of productivity parameters, the value stream map and operation rules related to process flow; and

providing on the fly a modification of at least one of the plurality of value stream metrics to the state engine to dynamically modify the simulation of the value stream map.

2. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, the method further comprising:

evaluating a performance of the value stream map based on the at least one modified value stream metrics.

3. The computer readable medium storing instructions to implement a method for creating a dynamic value network map of claim 2, further comprising:

determining an improvement for at least one value stream metric;

determining an adjustment to at least one productivity parameter from the plurality of productivity parameters that corresponds to the at least one value stream metric improvement; and

providing on the fly the at least one adjusted productivity parameter to the state engine to dynamically modify the simulation of the value stream map.

4. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, the method further comprising

establishing at least one new value stream metric;

and

providing on the fly the at least one new value stream metric to the state engine to dynamically modify the simulation of the value stream map.

5. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 4, the method further comprising:

dynamically updating the at least one new value stream metric; and

dynamically storing the updated at least one new value stream metric in a database.

6. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, wherein the value stream metrics are at least one of VAT, non-VAT, efficiency, takt time, objects completed, objects in progress, capacity, downtime, set-up and change over, load time, unload time, buffer size, and lead time.

7. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, wherein the value stream metrics are customized.

8. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, the method further comprising:

dynamically updating the plurality of value stream metrics; and

dynamically storing the updated value stream metrics in a database.

9. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 8, the method further comprising:

retrieving stored simulation data for a post-simulation analysis.

10. The computer readable medium storing instructions to Implement a method for creating a dynamic value stream map of claim 1, further comprising:

communicating data of the simulated value stream metrics to a graphical user interface; and

dynamically displaying value stream metrics data over a graphical representation of the process.

11. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 10, the method further comprising:

displaying concurrently stored simulated data of the value stream metrics from before and after the modification of the at least one of the plurality of value stream metrics.

12. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 10, wherein the graphical representation is a three dimensional representation.

13. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, the method further comprising:

exchanging data between the process flow and the dynamic value stream map.

14. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, wherein one of the value stream metrics corresponds to tracking data of one of the plurality of objects.

15. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 14, wherein the tracking data enables a dynamic allocation of the tracked object.

16. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 15, wherein a graphical representation of the tracked object is provided dynamically during the simulation of the dynamic value stream map.

17. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 15, wherein the graphical representation of the tracked object is provided dynamically after the simulation using the corresponding stored data.

18. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, the method comprising:

importing new data related to at least one of the process flow, the processed objects, and the cells; and

dynamically updating the value stream metrics during the simulation of the value stream map based on the imported data.

19. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 18, wherein the imported data is provided by external applications.

20. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 18, wherein the imported data corresponds to object, cell and/or buffer data.

21. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 18, wherein the imported data corresponds to alternate routing tables of the process flow or process operation rules.

22. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 1, wherein:

at least one of the plurality of cells has a plurality of sub-cells.

23. The computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 22, the method comprising:

establishing another plurality of value stream metrics corresponding to at least one of the plurality of objects, the plurality of sub-cells and interrelationships between the plurality of objects and the plurality of sub-cells;

providing on the fly a modification of at least one of the another plurality of value stream metrics to the state engine to dynamically modify the simulation of the value stream map.

24. The computer readable medium storing instructions to implement a method for creating a dynamic value stream map of claim 23, the method further comprising:

dynamically updating the another plurality of value stream metrics; and

analyzing the dynamically updated another plurality of value stream metrics to evaluate a performance of the value stream map.