Demand-driven collaborative scheduling for just-in-time manufacturing

• US 9,224,121 B2
• Filed: 09/09/2011
• Issued: 12/29/2015
• Est. Priority Date: 09/09/2011
• Status: Active Grant

• Current Assignee: SAP SE
• Original Assignee: SAP SE
• Inventors: Li, Wen-Syan, Wang, Heng, Sun, Gufei
• Primary Examiner(s): Fennema, Robert
• Assistant Examiner(s): Stewart, Fenyang
• Application Number:
  US13/229,199
• Publication Number:
  US 20130066455A1
• Time in Patent Office: 1,572 Days
• Field of Search: 700/100, 700/48, 700/99, 700/103, 705/14, 705/25, 705/29
• US Class Current: 1/1
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

A schedule manager may include a chromosome comparator configured to compare a plurality of schedule chromosomes, each schedule chromosome including a potential schedule of use of manufacturing resources within one or more time intervals in producing one or more items, and configured to compare each of the plurality of schedule chromosomes relative to constraints, to thereby output a selected subset of the plurality of schedule chromosomes. The schedule manager may include a chromosome combiner configured to combine schedule chromosomes of the selected subset to obtain a next generation of schedule chromosomes for output to the chromosome comparator and for subsequent comparison therewith of the next generation of schedule chromosomes with respect to the constraints, as part of an evolutionary loop of the plurality of schedule chromosomes between the chromosome comparator and the chromosome combiner, and a scheduler configured to select a selected schedule chromosome therefrom.

Claims

1. A computer system including instructions recorded on a non-transitory computer-readable medium and executable by at least one processor, the system comprising:

a schedule manager configured to cause the at least one processor to determine a schedule of each of a plurality of manufacturing resources used to manufacture one or more items, relative to one or more time intervals, wherein the schedule manager includes

an input handler configured to determine constraints related to the manufacturing resources and to the one or more items;

a chromosome comparator configured to compare a plurality of schedule chromosomes, each schedule chromosome representing a potential schedule and including a plurality of time periods and, for each of the plurality of time periods;

a supply quantity for at least one part used to manufacture the one or more items, and

a type of output produced by at least one manufacturing facility resource used to manufacture the one or more items,

the chromosome comparator also configured to evaluate each of the plurality of schedule chromosomes relative to the constraints, to thereby output a selected subset of highest scoring chromosomes of the plurality of schedule chromosomes, the evaluation accounting for a warehouse size, total items produced, and costs to switch outputs produced by a manufacturing resource during the potential schedule;

a chromosome combiner configured to combine schedule chromosomes of the selected subset of the plurality of schedule chromosomes to obtain a next generation of schedule chromosomes for output to the chromosome comparator and for subsequent comparison therewith of the next generation of schedule chromosomes with respect to the constraints, as part of an evolutionary loop of the plurality of schedule chromosomes between the chromosome comparator and the chromosome combiner; and

a scheduler configured to monitor the evolutionary loop and to select a selected schedule chromosome therefrom for implementation of the schedule based thereon.

2. The system of claim 1, wherein the constraints include at least one metric against which the potential schedules are judged, and wherein the schedule manager comprises a preference tuner configured to designate the at least one metric.

3. The system of claim 2 wherein the at least one metric includes a profit per item metric based on forecasted sales data and customer demand data for the one or more items.

4. The system of claim 2 wherein the at least one metric includes a relative utilization of the manufacturing resources in manufacturing the one or more items.

5. The system of claim 1 wherein the manufacturing resources include one or more of at least one parts production line, at least one assembly line, at least one parts supplier, and at least one warehouse.

6. The system of claim 1, wherein the schedule manager comprises a sales forecaster configured to forecast future sales data for the one or more items based on historical sales data thereof, and wherein the forecasted future sales data is included in the constraints.

7. The system of claim 1, wherein the schedule manager includes a simulation module configured to simulate a total number of items relative to total profit of the selected schedule over time.

8. The system of claim 1, wherein the schedule manager includes a what-if module configured to change a quantity of the manufacturing facility resources to simulate an effect of the change to the selected schedule over time.

9. The system of claim 1 wherein the chromosome combiner is configured to combine the schedule chromosomes including selecting pairs of schedule chromosomes and crossing over portions of each pair to obtain a child chromosome of the next generation.

10. The system of claim 1 wherein at least a portion of the evolutionary loop is executed using parallel processes in which each generation of schedule chromosomes is divided into sub-groups for parallel processing thereof.

11. The system of claim 1 wherein the scheduler is configured to select the selected schedule chromosome after a pre-determined number of generations of the evolutionary loop, or after determining that the selected chromosome satisfies the constraints to a pre-determined extent.

12. A computer-implemented method, comprising:

defining a schedule of each of a plurality of manufacturing resources used to manufacture one or more items, relative to one or more time intervals;

determining constraints related to the manufacturing resources and to the one or more items,

evaluating a plurality of schedule chromosomes, each schedule chromosome representing a potential schedule and including a plurality of time periods and, for each of the plurality of time periods;

a supply quantity for at least one part used to manufacture the one or more items, and

a type of output produced by at least one manufacturing facility resource used to manufacture the one or more items,

the evaluating including comparing each of the plurality of schedule chromosomes relative to the constraints, and accounting for a warehouse size, total items produced during the potential schedule, and costs to switch outputs produced by a manufacturing resource during the potential schedule;

outputting a selected subset of the evaluated plurality of schedule chromosomes;

combining schedule chromosomes of the selected subset of the plurality of schedule chromosomes to obtain a next generation of schedule chromosomes for subsequent evaluation therewith of the next generation of schedule chromosomes with respect to the constraints, as part of an evolutionary loop of the plurality of schedule chromosomes; and

selecting a selected schedule chromosome from the selected subset for implementation of the schedule based thereon.

13. The method of claim 12, wherein the constraints include forecasted future sales data based on historical sales data for the one or more items.

14. The method of claim 12 wherein the selected schedule chromosome is selected after a pre-determined number of generations of the evolutionary loop, or after a determination that the selected chromosome satisfies the constraints to a pre-determined extent.

15. A computer program product tangibly embodied on a non-transitory computer-readable storage medium and comprising instructions that, when executed by at least one processor, are configured to:

define a schedule of each of a plurality of manufacturing resources used to manufacture one or more items, relative to one or more time intervals;

determine constraints related to the manufacturing resources and to the one or more items,

evaluate a plurality of schedule chromosomes, each schedule chromosome representing a potential schedule and including a plurality of time periods and, for each of the plurality of time periods;

a supply quantity for at least one part used to manufacture the one or more items, and

a type of output produced by at least one manufacturing facility resource used to manufacture the one or more items, wherein evaluating the plurality of schedule chromosomes includes comparing each of the plurality of schedule chromosomes relative to the constraints and accounting for a warehouse size, total items produced during the potential schedule, and costs to switch outputs produced by a manufacturing resource during the potential schedule;

output a selected subset of the evaluated plurality of schedule chromosomes;

combine schedule chromosomes of the selected subset of the plurality of schedule chromosomes to obtain a next generation of schedule chromosomes for subsequent evaluation therewith of the next generation of schedule chromosomes with respect to the constraints, as part of an evolutionary loop of the plurality of schedule chromosomes; and

select a selected schedule chromosome from the selected subset for implementation of the schedule based thereon.

16. The computer program product of claim 15, wherein the constraints include at least one metric against which the potential schedules are judged, and wherein the at least one metric is received from a user.

17. The computer program product of claim 15, wherein the constraints include forecasted future sales data based on historical sales data for the one or more items.

18. The computer program product of claim 15, wherein the instructions, when executed, are configured to simulate an effect of the selected schedule over time.

19. The computer program product of claim 15, wherein the instructions, when executed, change a quantity of the manufacturing facility resources to simulate an effect of the change on the selected schedule over time.

20. The computer program product of claim 15 wherein the selected schedule chromosome is selected after a pre-determined number of generations of the evolutionary loop, or after a determination that the selected chromosome satisfies the constraints to a pre-determined extent.