System and method for dynamically simulating process and value stream maps

• US RE44,188 E1
• Filed: 02/09/2011
• Issued: 04/30/2013
• Est. Priority Date: 09/12/2005
• Status: Active Grant

• Current Assignee: Createasoft Incorporated
• Original Assignee: Createasoft Incorporated
• Inventors: Adra, Hosni I.
• Primary Examiner(s): PATEL, RAMESH B
• Application Number:
  US13/024,202
• Time in Patent Office: 811 Days
• Field of Search: 700 2- 3, 700 8- 9, 700/11, 700/18, 700/20, 700/23, 700/29, 700/86, 700/99, 703/2, 703/6, 703/13
• US Class Current: 700/29
• CPC Class Codes: G06Q 10/00 Administration; Management

Abstract

A computer readable medium comprising instructions which when executed by a computer system causes the computer to implement a method for dynamically improving a process flow is provided. For a plurality of cells, which define activities within the process flow and are characterized by a corresponding plurality of productivity data elements, the method triggers a state engine to simulate the process flow, with the state engine configured to manage all operations rules related to the process flow, and determines at least one process improvement. The method further identifies productivity data elements that correspond to the at least one process improvement, and dynamically modifies the identified productivity data elements to improve the process flow.

Claims

1. A non-transitory computer readable medium comprising instructions executed by a computer system to implement a method for dynamically improving a process flow, the process flow including a plurality of cells and a plurality of buffers connecting the plurality of cells, each of the plurality of cells characterized by a corresponding plurality of productivity parameters, the method comprising:

identifying a plurality of cells of the process flow, which are each characterized by a corresponding plurality of productivity parameters;

triggering a state engine to simulate the process flow, the state engine configured to manage the plurality of productivity parameters and all operations rules related to the process flow;

determining at least one process improvement;

identifying at least one productivity parameter that corresponds to the at least one process improvement; and

providing on the fly an adjustment of the at least one identified productivity parameter to the state engine to dynamically modify modifying the at least one identified productivity parameter during the simulation of to improve the process flow.

2. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 1, wherein the at least one improvement comprises mitigating a bottleneck, a delay, and/or a scheduling conflict.

3. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 1, wherein the process flow comprises a manufacturing process and the at least one improvement comprises to reducing operating costs of the manufacturing process.

4. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 1, wherein the at least one productivity parameter is one of routings of the process flow, cycle times of each of the plurality of cells, input resources, and output requirements of the process flow.

5. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 1, wherein the step of triggering the state engine further comprises:

pausing the state engine at a determined instant;

modifying the identified productivity parameters; and

retriggering the state engine.

6. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 1, the method further comprising:

generating custom reports during the simulation of the process flow.

7. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 1, the method further comprising:

communicating simulation data to a graphical user interface; and

dynamically displaying simulation data over a graphical representation of the process flow.

8. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 7, wherein the displayed simulation data represents constraints and bottlenecks.

9. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 7, wherein the graphical representation is a three dimensional representation.

10. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 1, the method further comprising:

importing data corresponding to the process flow; and

providing on the fly the imported data to the state engine to dynamically modify the simulation of the process flow.

11. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 10, wherein the imported data comprises modified productivity parameters.

12. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 10, wherein the imported data comprises at least one new cell.

13. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 10, wherein the imported data comprises modified routing tables of the process flow.

14. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 10, wherein the step of importing data enables forecasting bottlenecks, delays, and/or scheduling problems.

15. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 1, the method further comprising:

dynamically storing simulation data provided by the state engine in a database.

16. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 15, the method further comprising:

dynamically displaying stored simulation data for a post-simulation analysis.

17. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 15, wherein the dynamically stored data enables a tracking of an object navigating the process flow.

18. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 17, wherein the tracking of the object enables a dynamic allocation of the tracked object.

19. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 17, wherein the graphical representation and position of the tracked object is provided dynamically during the simulation.

20. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 17, wherein the graphical representation and position of the tracked object is provided dynamically after the simulation.

21. A non-transitory computer readable medium comprising instructions which when executed by a computer system causes the computer system to implement a method for dynamically improving a process flow, the method comprising:

identifying a sub-process, the sub-process comprising a plurality of sub-cells, the plurality of sub-cells defining activities within the sub-process flow and characterized by a corresponding plurality of productivity parameters;

triggering a state engine to simulate the sub-process flow, the state engine configured to manage the plurality of productivity parameters and operations rules related to the sub-process flow;

determining at least one sub-process improvement;

identifying productivity at least one productivity parameter that corresponds to the at least one sub-process improvement; and

providing on the fly an adjustment of the at least one identified productivity parameter to the state engine to dynamically modify the simulation of the sub-process flow.

22. A non-transitory computer readable medium comprising instructions which when executed by a computer system causes the computer to implement a method for creating a dynamic value stream map of a process flow, the value stream map represented by a plurality of value stream metrics corresponding to a plurality of cells of the process and to of interrelationships between the plurality of cells, the method comprising:

triggering a state engine to simulate the value stream map, the state engine configured to manage the plurality of value stream metrics and operations rules related the value stream map;

evaluating the value stream metrics in the state engine during the simulation of the value stream map; and

updating on the fly the value stream map with the evaluated value stream metrics to provide a dynamic value stream map.

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

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

24. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 22, wherein the value stream metrics are at least one of value added time (VAT), non-VAT, efficiency, take time, objects completed, objects in progress, capacity, downtime, set-up and change over, load time, unload time, buffer size, and lead time.

25. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 22, wherein the value stream metrics are customized.

26. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 23, further comprising:

determining at least one dynamic value stream map improvement;

identifying at least one value stream metric that corresponds to the at least one value stream improvement; and

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

27. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 22, the method further comprising:

dynamically storing data corresponding to the evaluated value stream metrics in a database.

28. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 27, the method further comprising:

dynamically displaying stored simulation data for a post-simulation analysis.

29. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 22, further comprising:

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

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

30. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 29, wherein the graphical representation is a three dimensional representation.

31. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 22, the method further comprising:

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

32. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 22, wherein one of the value stream metrics corresponds to tracking data of an object.

33. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 32, wherein the tracking data enables a dynamic allocation of the tracked object.

34. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 33, wherein a graphical representation and position of the tracked object is provided dynamically during the simulation of the dynamic value stream map.

35. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 34, wherein the graphical representation and position of the tracked object is provided dynamically after the simulation using the corresponding stored data.

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

providing on the fly new data corresponding to the value stream metrics to the state engine thereby dynamically modifying the simulation of the value stream map.

37. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 36, wherein the data is provided by external applications.

38. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 36, wherein the provided data corresponds to cell and/or buffer data.

39. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 36, wherein the provided data corresponds to alternate routing tables of the process flow or process definition methods.

40. A non-transitory computer readable medium comprising instructions executed by a computer system to implement a method for creating a dynamic value stream map of a sub-process flow, the value stream map represented by a plurality of value stream metrics corresponding to a plurality of sub-cells of the process and to interrelationships between the plurality of sub-cells, the method comprising:

triggering a state engine to simulate the value stream map, the state engine configured to manage the plurality of value stream metrics and operations rules related to the value stream map;

dynamically evaluating the value stream metrics in the state engine during the simulation of the value stream map; and

updating on the fly the value stream map with the evaluated value stream metrics to provide a dynamic value stream map.

41. The non-transitory computer readable medium comprising instructions to implement a method for creating a dynamic value stream map of claim 40, the method further comprising:

analyzing the dynamically evaluated value stream metrics to evaluate a performance of the value stream map.

42. A non-transitory computer readable medium comprising instructions executed by a computer system to implement a method for dynamically modifying a flow of a process, the process characterized by a plurality of cells, which are each characterized by a corresponding plurality of productivity parameters, and interrelationships between the plurality of cells, the method comprising:

triggering a state engine to simulate the process flow, the state engine configured to manage the plurality of productivity parameters and operations rules related to the process flow; and

providing on the fly process data to the state engine, thereby dynamically modifying the simulation of the process flow.

43. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying the process flow of claim 42, wherein the provided process data is provided by external applications.

44. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying the process flow of claim 42, wherein the provided process data corresponds to cell and/or buffer data.

45. The non-transitory computer readable medium comprising instructions to implement a method for dynamically modifying a process flow of claim 42, wherein the provided process data corresponds to alternate routing tables of the process flow process definition methods.

46. A non-transitory computer readable medium comprising instructions which when executed by a computer system causes the computer to implement a method for dynamically creating a process flow, the method comprising:

triggering a state engine to simulate the process flow, the state engine configured to manage all operations rules related to the process flow;

providing on the fly process data to the state engine, the process data corresponding to a plurality of cells, which are each characterized by a corresponding plurality of productivity parameters, and interrelationships between the plurality of cells, thereby incorporating the provided process data to dynamically create the process flow.

47. The non-transitory computer readable medium comprising instructions to implement a method for dynamically creating the process flow of claim 46, wherein the provided process data is provided by external applications.

48. The non-transitory computer readable medium comprising instructions to implement a method for dynamically creating the process flow of claim 47, wherein the provided process data corresponds to cell and/or buffer data.

49. The non-transitory computer readable medium comprising instructions to implement a method for dynamically creating a process flow of claim 47,

wherein the provided process data corresponds to alternate routing tables of the process flow or process definition methods.

50. A non-transitory computer readable medium comprising instructions executed by a computer system to implement a method for dynamically creating a value stream map corresponding to a process flow, the value stream map represented by a plurality of value stream metrics corresponding to a plurality of cells of the process and to interrelationships between the plurality of cells, the method comprising:

triggering a state engine to simulate the process flow, the state engine configured to manage operations rules related to the process flow;

and

providing on the fly value metrics data to the state engine, thereby dynamically incorporating the provided data to dynamically create the value stream map.

51. The non-transitory computer readable medium comprising instructions to implement a method for dynamically creating the value stream map of claim 50, wherein the provided data is provided by external applications.

52. The non-transitory computer readable medium comprising instructions to implement a method for dynamically creating the value stream map of claim 50, wherein the provided data corresponds to cell and/or buffer data.

53. The non-transitory computer readable medium comprising instructions to implement a method for dynamically creating the value stream map of claim 50, wherein the provided data corresponds to alternate routing tables of the process flow or process definition methods.