Continuous production planning using a transition matrix

• US 8,965,549 B2
• Filed: 10/14/2013
• Issued: 02/24/2015
• Est. Priority Date: 06/19/2002
• Status: Expired due to Fees

• Current Assignee: Blue Yonder Group, Inc. (Panasonic Holdings Corporation)
• Original Assignee: JDA Software Group Incorporated (RedPrairie Holding Incorporated)
• Inventors: Slocum, Gregory H., Iyer, Anand, Brigham, John D.
• Primary Examiner(s): PATEL, RAMESH B
• Application Number:
  US14/053,480
• Publication Number:
  US 20140046467A1
• Time in Patent Office: 498 Days
• Field of Search: 705 712- 713, 705/7.23, 700 99-100, 700/103, 700/105
• US Class Current: 700/100
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Abstract

A method for continuous production planning includes identifying a forbidden transition associated with production of first and second end products. The forbidden transition indicates that a manufacturer should not produce the first and second end products consecutively. The method also includes identifying a bridge product associated with the forbidden transition. The bridge product represents a product that the manufacturer could produce between production of the first and second end products. The method further includes determining a quantity of the bridge product that could be produced by the manufacturer. In addition, the method includes scheduling production of the first and second end products and the bridge product. At least a portion of the quantity of the bridge product is scheduled for production between the production of the first and second end products.

Claims

1. A system, comprising:

production equipment that produces a first end product, a second end product, and a transition product during transition from producing the first end product and the second end product;

a production server comprising a processor and memory, wherein the production server identifies the transition product, stores one or more rules in memory; and

when the transition product produced by the production equipment satisfies the one or more rules, the production equipment produces the transition product; and

when the transition product produced by the production equipment does not satisfy the one or more rules, the production server identifies at least one bridge product and the production equipment produces the bridge product.

2. The production system of claim 1, wherein the production server identifies at least one bridge product by:

generating a transition matrix comprising a source node associated with the first end product and a destination node associated with the second end product; and

identifying one or more articulation points between the source and destinations nodes, wherein each articulation point of the one or more articulation points identifies a bridge product.

3. The production system of claim 1, wherein the production server receives demand information from a supply chain entity, and the production server further identifies at least one bridge product by:

identifying each of the one or more articulation points associated with a bridge product having no demand; and

removing each of the one or more articulations points associated with a bridge product having no demand.

4. The production system of claim 3, the demand information comprising existing supply chain demand for a bridge product, and the one or more rules comprises:

determining a maximum amount of the bridge product that the production equipment can produce;

when the existing supply chain demand is less than the maximum amount of the bridge product, the production equipment produces an additional quantity of bridge product equal to the maximum amount of the bridge product minus the total existing supply chain demand; and

when the total existing supply chain demand is greater than the maximum amount of the bridge product, the additional quantity of the bridge product equals zero.

5. The production system of claim 4, wherein the one or more rules further comprises:

set priority of exiting demand higher than priority of additional demand

set minimum campaign length of additional demand to one lot.

6. The production system of claim 4, wherein determining a maximum amount of the bridge product that the production equipment can produce comprises:

identify one or more pairs of end products associated with the bridge product;

determine a transition block time for each pair of end products;

determine a number of time units in a planning horizon;

determine an upper bound of a number of lots of the bridge product for each pair of end products; and

determine a total number of lots of the bridge product that the production equipment can produce using the upper bound of the number of lots of the bridge product.

7. The production system of claim 4, wherein the production server receives demand information by one or more of:

receiving sales information from a point of sales terminal;

receiving sales predictions from one or more of a manufacturer, supplier, and retailer;

receiving availability information of one or more raw materials from a raw material supplier;

receiving sales histories of end products;

receiving price histories of end products; and

receiving demand prediction information for one or more of the first and second end products, the transition product, or the bridge product.

8. A non-transitory computer-readable medium embodied with production software, the software when executed using one or more computers is configured to:

identify a transition product, wherein the transition product is produced by production equipment that produces a first end product, a second end product, and the transition product during transition from producing the first end product and the second end product;

store one or more rules;

direct the production equipment to produce the transition product when the transition product produced by the production equipment satisfies the one or more rules; and

identify at least one bridge product and direct the production equipment to produce the bridge product when the transition product produced by the production equipment does not satisfy the one or more rules.

9. The non-transitory computer-readable medium embodied with production software of claim 8, wherein the software identifies at least one bridge product by:

generating a transition matrix comprising a source node associated with the first end product and a destination node associated with the second end product; and

identifying one or more articulation points between the source and destinations nodes, wherein each articulation point of the one or more articulation points identifies a bridge product.

10. The non-transitory computer-readable medium embodied with production software of claim 8, wherein the software receives demand information from a supply chain entity, and the software further identifies at least one bridge product by:

identifying each of the one or more articulation points associated with a bridge product having no demand; and

removing each of the one or more articulations points associated with a bridge product having no demand.

11. The non-transitory computer-readable medium embodied with production software of claim 10, the demand information comprising existing supply chain demand for a bridge product, and the one or more rules comprises:

determining a maximum amount of the bridge product that the production equipment can produce;

when the existing supply chain demand is less than the maximum amount of the bridge product, the production equipment produces an additional quantity of bridge product equal to the maximum amount of the bridge product minus the total existing supply chain demand; and

when the total existing supply chain demand is greater than the maximum amount of the bridge product, the additional quantity of the bridge product equals zero.

12. The non-transitory computer-readable medium embodied with production software of claim 11, wherein the one or more rules further comprises:

set priority of exiting demand higher than priority of additional demand

set minimum campaign length of additional demand to one lot.

13. The non-transitory computer-readable medium embodied with production software of claim 11, wherein determining a maximum amount of the bridge product that the production equipment can produce comprises:

identify one or more pairs of end products associated with the bridge product;

determine a transition block time for each pair of end products;

determine a number of time units in a planning horizon;

determine an upper bound of a number of lots of the bridge product for each pair of end products; and

determine a total number of lots of the bridge product that the production equipment can produce using the upper bound of the number of lots of the bridge product.

14. The non-transitory computer-readable medium embodied with production software of claim 10, wherein the software receives demand information by one or more of:

receiving sales information from a point of sales terminal;

receiving sales predictions from one or more of a manufacturer, supplier, and retailer;

receiving availability information of one or more raw materials from a raw material supplier;

receiving sales histories of end products;

receiving price histories of end products; and

receiving demand prediction information for one or more of the first and second end products, the transition product, or the bridge product.

15. A method of production comprising:

identifying, by a computer, a transition product, wherein the transition product is produced by production equipment that produces a first end product, a second end product, and the transition product during transition from producing the first end product and the second end product;

storing, by the computer, one or more rules;

directing, by the computer, the production equipment to produce the transition product when the transition product produced by the production equipment satisfies the one or more rules; and

identifying, by the computer, at least one bridge product and direct the production equipment to produce the bridge product when the transition product produced by the production equipment does not satisfy the one or more rules.

16. The method of claim 15, wherein identifying at least one bridge comprises:

generating, by the computer, a transition matrix comprising a source node associated with the first end product and a destination node associated with the second end product; and

identifying, by the computer, one or more articulation points between the source and destinations nodes, wherein each articulation point of the one or more articulation points identifies a bridge product.

17. The method of claim 15, wherein identifying at least one bridge product further comprises:

receiving, by the computer, demand information from a supply chain entity;

identifying, by the computer, each of the one or more articulation points associated with a bridge product having no demand; and

removing, by the computer, each of the one or more articulations points associated with a bridge product having no demand.

18. The method of claim 17, the one or more rules comprises:

determining, by the computer, a maximum amount of the bridge product that the production equipment can produce;

directing, by the computer, the production equipment to produce an additional quantity of bridge product equal to the maximum amount of the bridge product minus the total existing supply chain demand when the existing supply chain demand is less than the maximum amount of the bridge product; and

directing, by the computer, the production equipment to produce no additional quantity of bridge product, when the total existing supply chain demand is greater than the maximum amount of the bridge product.

19. The method of claim 18, wherein the one or more rules further comprises:

set priority of exiting demand higher than priority of additional demand

set minimum campaign length of additional demand to one lot.

20. The method of claim 18, wherein determining a maximum amount of the bridge product that the production equipment can produce comprises:

identify one or more pairs of end products associated with the bridge product;

determine a transition block time for each pair of end products;

determine a number of time units in a planning horizon;

determine an upper bound of a number of lots of the bridge product for each pair of end products; and

determine a total number of lots of the bridge product that the production equipment can produce using the upper bound of the number of lots of the bridge product.