WO1993005476A1 - Procede de planification de la capacite productive constante - Google Patents

Procede de planification de la capacite productive constante Download PDF

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Publication number
WO1993005476A1
WO1993005476A1 PCT/US1992/007504 US9207504W WO9305476A1 WO 1993005476 A1 WO1993005476 A1 WO 1993005476A1 US 9207504 W US9207504 W US 9207504W WO 9305476 A1 WO9305476 A1 WO 9305476A1
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Prior art keywords
tasks
task
determining
schedule
production schedule
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PCT/US1992/007504
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English (en)
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Henry Engelman
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Timephaser Corporation
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Priority to EP92920591A priority Critical patent/EP0603326A4/fr
Priority to CA002116982A priority patent/CA2116982A1/fr
Publication of WO1993005476A1 publication Critical patent/WO1993005476A1/fr

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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Definitions

  • This invention relates generally to a method of managing repetitive tasks, and more specifically to a process which applies the critical path method to repetitive tasks having constant rates of production.
  • repetitive tasks are found in a wide variety of settings, including factory assembly lines and construction sites. Staking out individual lots for a tract-home subdivision, mounting picture tubes to television set cabinets, and bolting transmissions to engines illustrate various types of repetitive tasks within larger projects.
  • FIGURE 1 is a graphical representation of continuous rates of production for a plurality of interrelated tasks.
  • the X-axis is labelled in units of time such as days or hours.
  • the Y-axis is labelled to designate the individual units on which tasks are to be performed.
  • the work performed by a crew completing a task is shown on the graph as a line having a slope proportional to the output for that task.
  • the graph may be used to indicate the outputs of work stations along an assembly line. Lines having steep slopes indicate tasks for which the rate of completion is relatively rapid, whereas lines having more horizontal slopes indicate tasks for which the rate of completion is slow. Many of these tasks have precedence relationships, meaning that a given task cannot be performed until one or more previous tasks have been completed.
  • FIGURE 2 Another example of a line of balance calculation is shown in FIGURE 2.
  • the line of balance specifies the types of components which must be available at specific points in time to achieve a constant rate of production.
  • a shortcoming of the line of balance method is that it is very difficult to update the graphical displays to reflect progress that deviates from the original schedule, or unexpected delays. In many cases, virtually the entire series of graphs has to be redrawn to provide an accurate, updated schedule. In practice, however, line-of-balance graphs are seldom updated, due to the difficulty involved.
  • FIGURE 3 is a graphical representation of another prior-art method for schedule planning, termed the critical path method (CPM).
  • CPM analyzes a complex project by dividing the project into individual tasks with serial and parallel time-precedence relationships.
  • Serial relationships refer to interdependent tasks, where a first task must be completed prior to commencing a second task.
  • Parallel relationships involve tasks which may be implemented simultaneously.
  • the interrelationships between the tasks may be modeled as a network. Each task is represented by a point or node on the network.
  • a start date is specified for the first task, and a duration is assigned to each task.
  • the second special aspect of CPM is that there are a number of special types of constraints, or "plugs", that can be applied to a work item above and beyond the logical relationships.
  • constraints are As-Late-As-Possible (ALAP). If an ALAP plug is assigned to the early start date of task A, then the early start date will be delayed as much as possible, i.e., until any further delay would cause negative float (delay of a required due date further in the network).
  • the CPM scheduling process accepts data representing the coded network interactively and/or in batch mode.
  • a forward pass and backward pass are executed through the network to establish dates and priorities for all tasks in the network.
  • the earliest possible start and finish dates for each task are determined in a step-wise fashion.
  • the process commences at the project starting date and the durations of individual tasks are added to the starting date, until an expected finish date is determined.
  • the earliest start date of a task is equal to the latest starting date of the preceding tasks plus the duration of the preceding task.
  • the finish date of each task is its start date plus its duration, minus one working day. In this manner, the finish date of the last task determines the completion date of the project.
  • the backward pass through the network performs the aforementioned operations in reverse order to establish the latest possible completion dates.
  • the latest possible completion date may be defined as the last date for which a task may be accom ⁇ plished without missing the target project completion date.
  • the difference between a task's earliest possible completion date and latest possible completion date is termed "slack" or "float '.
  • CPM reports include tabular reports (FIGURE 4) and Gantt or bar charts (FIGURE 5).
  • CPM critical path method
  • the critical path method provides a useful tool for schedule planning, the amount and complexity of data entry required to use CPM for repetitive jobs, and the volume of printed reports required to interpret the schedules, renders CPM practical for only a small number of repetitive tasks on a small number of jobs. For example, a typical construction tract of 100 homes requiring 150 tasks per home would involve data entry of 15,000 tasks and determination of at least 30,000 precedence relation ⁇ ships. Using the most compact reporting format available, such a report would generate several hundred pages of data.
  • MRP II Manufacturing Requirements and Planning
  • assembly line scheduling is based on heuristic solutions of different capacity resource planning algorithms addressing idle machine time and uncompleted assemblies. This approach, plus the inherent changeability of data and size of the problems considered here, render MRP II unsuitable for scheduling a large number of repetitive tasks.
  • the scheduling method should be flexible to allow for frequent updates in accordance with actual job pro- sion.
  • the method should also provide ease of updating.
  • the graphical output should provide essential scheduling information in a concise, easily-interpreted format.
  • required data providing and data entry operations should be kept to a minimum and be capable of being performed with minimal training and expertise.
  • the present invention provides such a method.
  • the invention provides an improved process for scheduling production tasks.
  • the process combines the constant rate of production method with the critical path method, thereby providing an enhanced process for creating a production schedule.
  • the process allows a user to plan a schedule and to track progress of repetitive tasks for large and complex jobs.
  • the process requires minimal data entry, and may be updated to reflect actual job progress.
  • a production schedule is produced in a concise, easily-interpreted format.
  • the process commences when a user enters task data into a data processing device.
  • the user need not enter data for all the units of a given job; task data pertaining to one unit is sufficient.
  • This data preferably includes the description, duration, and preceding work items for each task.
  • Each task is assigned a unique code number.
  • the user specifies the tasks which are to be repeated on additional units. For these repetitive tasks, the user may also enter the number of units to be completed per day, the number of crews or work stations per task, and the minimum number of units required for continuous work. The total number of units to be produced is also specified.
  • the data processing device determines a sequence, for reporting purposes, of repetitive tasks for a single "template" unit.
  • the sequence is determined by starting at the first task to be performed and making a forward pass through subsequent tasks.
  • the earliest possible starting dates for the tasks are determined, based upon the duration of previous tasks and the starting date of the first task.
  • the data for the template unit is transformed into a critical path method (CPM) network for an entire job by determining the repetitive tasks with their respective durations and precedence relationships for each additional unit in the job. Precedence relationships between same tasks but different units must also be considered. These latter precedence relationships take into account the movement of crews through units and/or the movement of units through work stations. Special constraints may be incorporated into the network in order to provide continuous work for the crews.
  • CPM critical path method
  • the data processing device utilizes the CPM network to calculate earliest and latest possible starting and finishing dates for each task performed on each unit.
  • the latest possible starting date is the last day for which a task may be started which permits the project to be finished on time.
  • the calculation of early and late dates is imple- mented using CPM techniques which are well-known.
  • eariiest possible start and finish dates are calculated by conducting a first forward pass through the data.
  • the latest possible start and finish dates are calculated by conducting a first backward pass through the data.
  • a planning schedule consisting of start and finish dates for each task and each unit is created.
  • the schedule is displayed in a form which is an improvement over traditional Gantt bar charts.
  • a time line is displayed on the X-axis, and configured so that each column can accept multi-digit unit numbers.
  • a list of work items is displayed on the Y-axis, and includes only those tasks which are repetitive in nature.
  • Conventional horizontal bars within the schedule showing the start and finish dates for each task have been replaced by the unit number being worked on. The unit number is aligned to indicate the corresponding task at the X-axis, and the corresponding date at the Y-axis.
  • the CPM network may be modified throughout the course of a job, as desired.
  • Completed tasks are entered into the data processing device and are then removed from the schedule of remaining work. In this manner, an updated schedule is calculated which optimizes production based upon actual task progress and planned performance rates.
  • the updated schedule reflects the most efficient manner in which the remaining unfinished tasks may be completed.
  • the present invention plans the schedule and tracks the progress of repetitive work for relatively complex jobs using a method that requires minimal data entry.
  • the schedule is presented, and progress data are accepted, in an intuitive and compact form.
  • the method of the invention converts graphical representations from a line of balance format into a tabular format that is intuitive and compact and able to be produced by automated non-graphical means (i.e., character mode as opposed to all-points addressable, or bit-mapped, mode).
  • the method creates and utilizes an inference machine that accepts as input the CPM network for one unit and determines the various ways to create the CPM network for multiple units with the special line of balance constraints.
  • the CPM calculation method is employed with modifications to meet special line of balance constraints. Progress reporting data is accepted in tabular or graphical format and converted into CPM data.
  • FIGURE 1 is a prior-art manual graphical representation of the constant rate of production method.
  • FIGURE 2 is a prior-art graphical representation of the line of balance method.
  • FIGURE 3 is a prior-art graphical representation of the critical path method.
  • FIGURE 4 is a prior-art schedule report setting forth a planned schedule for implementing a plurality of interrelated tasks.
  • FIGURE 5 is a prior-art Gantt bar chart setting forth a planned schedule for implementing a plurality of interrelated tasks.
  • FIGURES 6 and 7 are flowcharts depicting the schedule planning method of the present invention.
  • FIGURE 8 is a chart illustrating the information which is input to the schedule planning method of the preferred embodiment of the present invention.
  • FIGURE 9 is a chart illustrating the information which is output by the schedule planning method of the preferred embodiment of the present invention.
  • FIGURE 10 is a flowchart illustrating the process of creating relationships between different tasks to be performed on the same unit.
  • FIGURE 11 is a flowchart illustrating the process of creating relationships between the same tasks to be performed on different units.
  • FIGURE 12 is a flowchart depicting the process of creating special constraints for the purpose of scheduling continuous work.
  • FIGURE 13 is a diagrammatic representation of exemplary relationships between a plurality of interrelated tasks and a plurality of units.
  • FIGURE 14 is a schedule printout which illustrates the results of the implementation of special constraints to provide continuous work.
  • FIGURE 6 illustrates the scheduling method of the present invention, which combines the line-of-balance method with CPM.
  • a CPM network for a single "template” unit is defined as comprising a plurality of "tasks” (e.g., "stake lot", “drill foundation”).
  • the term “work item” (Wl) is defined to be a task performed on a particular unit on a job.
  • the invention generates a CPM network from the template unit CPM network in which each Work Item (Wl) for a job is represented as a node WI /7 .
  • WI /7 represents a Work Item comprising task/ performed on unit / (a third index, for job number, could be used, but is generally omitted for purposes of clarity).
  • An example of the Wl codes thus formed is shown in
  • FIGURE 5 The Wl code "1-002-106" refers to Task #106 (Drill Foundation) to be performed on Unit #002 for Job #1 (Bush Hill development).
  • step 1 a user enters the task data for a single "template” unit (i.e., any one of the actual units for the job) into a computer.
  • This data includes the code, description, duration, and/or preceding tasks for each task (for all
  • FIGURE 8 shows a chart illustrating an example of the information which is input to the schedule planning method of the preferred embodiment of the present invention.
  • the task data for the single template will be used as a template for creating the CPM network for multiple units.
  • step 2 the user specifies which tasks are to be repeated in additional units. For these repetitive tasks, the user enters: a. the number of units required to be produced per day, if > 1 ; b. the number of crews or work stations per task, if > 1 ; c. the minimum number of units required for continuous work, if > 1 (the minimum number of units required for continuous work may be defined as the "bucket size").
  • This data is shown in FIGURE 8 as being entered into corresponding rows with the basic task data for the template unit.
  • step 3 a default sequence for listing the repetitive tasks in reports (i.e., down the
  • Y-axis as shown in FIGURE 9) is determined by the computer from the data entered in steps 1 and 2.
  • a suitable default sequence is obtained by performing a CPM forward pass on the template, and using a sorted listing of the early start date for all tasks to define the default sequence. A user may override the default listing sequence if desired.
  • a CPM network database is created from the input data.
  • the CPM network database consists of: a. a CPM network for the single template unit (including any non-repetitive tasks); b. the repetitive tasks with their durations for each additional unit (i.e., all repetitive Work Items Wl,y); c. precedence relationships between different tasks performed on the same unit for all units (see FIGURES 10 and 13); d. precedence relationships between the same tasks performed in different units that take into consideration the movement of crews through units (or units through work-stations) (see FIGURES 11 and 13); e. special constraints to implement bucket size (see FIGURES 12 and 14); f. extra intermediate sequencing to add new rows in reports where needed for multiple crews and multiple units per day (see FIGURES 9 and 11). Greater detail as to the preferred method for generating such information is set forth below in conjunction with the description of FIGURES 10-14.
  • step 6 the CPM method of calculation is applied in known fashion to the CPM network thus created in order to compute the early and late start and finish dates for each Work Item Wl,y.
  • Automated computation of CPM networks is well known (see, e.g., O'Brien, "Scheduling Handbook", McGraw-Hill, p.47, with references on p. 72 and p. 143).
  • the extension to the standard CPM procedure used in the present invention to accommodate the special ALAP constraints involves a second forward and backward CPM pass in which early start and finish dates of the constrained Work Item are replaced with late start and finish dates. In effect, this second pass delays the affected work items as much as possible. For instance, refer to FIGURE 14, where Task 134 (“Pour Piers”) has been delayed on units 3 and 4.
  • step 7 the computer creates a printed production schedule, a copy of which is the
  • the preferred format of the turn-around report is shown in FIGURE 9, and is an improvement to prior art Gantt (bar) charts (see FIGURE 5).
  • the preferred report format differs from a Gantt chart in that: a. the time-line (X-axis) is spread out so that each column can accept at least a multi-digit unit number; b. the lengthy list of work items Wl ; y (Y-axis) has been replaced by the shorter list of repetitive tasks (i.e., Wl 0 ); c.
  • the report format displays the progress required to achieve a constant rate of production (or "line of balance").
  • a field superintendent marks the completed tasks for each unit on the turn-around document. After marking on the report the completed work at a given cut-off date, the report is returned to be used for purposes of additional data entry to prepare an updated turn-around report.
  • Step 9 involves the creation of an on-line (i.e., viewed interactively on a computer terminal) computer display that is essentially a visual duplicate of the turn-around document. While the unit numbers referred to in step 7c above are depicted as simply a row of numbers printed on paper, for interactive data entry at a computer terminal, it is preferable to use discrete fields on discrete records for a data entry clerk to modify.
  • step 10 the data entry clerk enters into the computer the completed task and unit information indicated by the entries made by the field superintendent on the turn ⁇ around document. This may be done, for example, by overwriting with a zero each displayed unit number for which a task has been completed.
  • step 11 the computer updates the original database from which the CPM network was computed by marking as completed those Work Items Wl ; y in the database corre ⁇ sponding to the entries made by the data entry clerk.
  • Steps 7 through 10 associate tasks with units, for compactness of presentation of the production schedule (FIGURE 9).
  • the data captured in step 10 has to be translated back to Work Items Wl,y. This is done by deducing which Work Item WL corresponds to each field that the data entry clerk has marked as completed. Each such Work Item Wl,y then gets its remaining duration set to zero. When the CPM network is recalculated, work items with remaining duration equal to zero are considered completed and the updated schedule is thus calculated.
  • steps 6 through 12 are repeated using the modified CPM network database every update, until the end of the project.
  • FIGURE 10 is a flowchart illustrating the process of creating precedence relationships between different tasks to be performed on the same unit.
  • the process is repeatedly performed in a series of nested loops.
  • the innermost loop repeats the process for every template relationship. Relationships between current work items and preceding work items are established.
  • a mid-level loop repeats the process for every unit/ from 1 to m.
  • the outermost loop repeats the process for every template work item/ from 1 to n.
  • the program commences at block 1000, where the next preceding work item related to the current work item is read from the input shown in FIGURE 9.
  • a test is performed at block 1002 to see whether the current or preceding work items are repetitive. If not, the program loops back to block 1000. If the current and/or preceding work items are repetitive, the program proceeds to block 1012, where a test is performed to determine whether or not the current work item is repetitive but the preceding item is not repetitive. If these conditions are met, a data record is created linking the current item to the non-repetitive preceding item in a precedence relationship, at block 1018. The current work item-preceding work item precedence relationship data record is added to the CPM network database at block 1022.
  • the program then loops back to block 1000, where the next work item is read. If the conditions at block 1012 are not met, program control transfers to block 1014, where a test is performed to determine whether or not the current work item is not repetitive but the preceding time is repetitive. If these conditions are met, the preceding work time is linked to the current non-repetitive item at block 1020, and the current work item-preceding work item precedence relationship data record is added to the CPM database at block 1022. The program then loops back to block 1000 where the next work item is read. The negative branch from block 1014 leads to block 1022.
  • FIGURE 11 is a flowchart illustrating the process of creating precedence relationships between the same tasks to be performed on different units. The program is executed repeatedly within a series of nested loops, as previously described with reference to
  • FIGURE 10 The program commences at block 1100, where a work item data record
  • the unit counter is incremented, and at block 1107 the unit counter is divided by the number of crews.
  • the result is an integer AA and a remainder BB as indicated at block 1109.
  • the remainder BB is placed into a unit table (table 7) at block 1111.
  • Table T is used to indicate that extra intermediate sequences of tasks are needed for reporting purposes, resulting in the addition of new rows in reports to indicate multiple crews and multiple units per day.
  • An example of such added rows is shown in FIGURE 9, where tasks 100 and 140 have multiple row entries.
  • the duration of the work item is divided by the number of crews.
  • the result is an integer CC and a remainder DD, as shown in block 1115.
  • Block 1117 tests to see whether or not the remainder DD is greater than zero. If so, 1 is added to CC at block 1119, and the program progresses to block 1121. If the remainder DD is not greater than zero, the program progresses directly to block 1121.
  • the precedence relationship time lag is set to CC.
  • the current work item- preceding work item precedence relationship data record (which includes the time lag) is added to the CPM database at block 1123, and the program loops back to block 1100.
  • the negative branch from block 1103 leads to block 1131 , where the program checks to see whether or not the number of units per day is greater than 1. If not, the program jumps ahead to block 1123, where the current work item-preceding work item precedence relationship data record is added to the CPM database. If the number of units per day is greater than 1 , the unit counter is incremented at block 1135, and the counter is divided by the number of units per day at block 1137. The result of the division is an integer FF and a remainder GG, as set forth in block 1139. At block 1141, the remainder GG is placed info table T. A test is performed at block
  • FIGURE 12 is a flowchart illustrating the procedure for creating as-late-as-possible (ALAP) constraints, for the purpose of providing continuous work if feasible.
  • the procedure is performed repeatedly, within a series of nested loops.
  • the mid-level loop performs the program for every template relationship between a current work item and a preceding work item.
  • the program commences at block 1201 , where a counter is initialized.
  • a test is performed to ascertain whether or not the current and preceding tasks are both repetitive. If not, the program loops back to block 1201.
  • Bucket size refers to the minimum number of units required to provide continuous work for a work crew.
  • the negative branch from block 1205 transfers program control back to block 1201.
  • the affirmative branch leads to block 1207, where the counter is divided by the bucket size.
  • the result of this operation is an integer HH and a remainder KK, as shown at block 129.
  • the program tests to see if KK is equal to zero at block 1211. If not, the program loops back to block 1201 ; otherwise, the program continues to block 1213, where an as-late-as-possible (ALAP) constraint for the current work item is added to the CPM network database. The program then returns to block 1201.
  • ALEP as-late-as-possible
  • FIGURE 13 is a block diagram illustrating different groups of precedence relationships.
  • Each block 1301, 1303, 1305, 1307, 1309, 1311, 1313, 1315, 1317, 1319 depicts a work item WL.
  • Precedence relationships between different tasks to be performed on the same unit are denoted by arrows pointing in a horizontal direction (e.g., between blocks 1301 and 1303, blocks 1309 and 1311, blocks 1315 and 1317, etc.).
  • Precedence relationships between the same tasks but different units are denoted by arrows pointing downward and to the right (e.g., between blocks 1303 and 1309, blocks 1305 and 1311, blocks 1311 and 1317, etc.).
  • FIGURE 14 is a diagram which illustrates the technique of bucketing to provide continuous work for a work crew.
  • bucketing occurs for the task designated by task code 134, "pour piers".
  • the work crew is scheduled to perform this task on three consecutive days (June 13, 19, and 20) for three respective units numbered 3, 4, and 5. Due to the precedence relationships between the tasks, providing continuous work for the pier-pouring crew with respect to units 1 and 2 in the present example would delay the job.
  • the bucket for units 3, 4, and 5 is implemented by starting work on unit 3 as late as possible without delaying the job.
  • CPM network database is generated as described above, conventional CPM data processing is applied to the database (taking into account all defined precedence relationship types, time lags, and ALAP constraints) to generate a CPM production schedule. From such information, plus the default reporting sequence determined in step 3 and Table T, a report is generated in the format shown in FIGURE 9. That is, each task in the CPM network database is listed at least once along the Y-axis in the sequence determined in step 3. Additional rows are added for a task where indicated by corresponding entries for that task in Table 7. The work item schedule dates determined when the CPM calculation was applied to the CPM network database provide the X-axis coordinates for each unit for each task.
  • the present invention provides an improved process for scheduling production tasks which combines the constant rate of production method with the critical path method.
  • the method allows a user to plan a schedule and to track progress of repetitive tasks for large and complex jobs.
  • the process requires minimal data entry, and may be readily updated to reflect actual job progress.
  • a production schedule is produced in a concise, easily-interpreted format.
  • the invention provides a one-step direct solution, rather than the prior art iterative approach that required user-interaction to successively improve a heuristic solution.
  • a number of embodiments of the present invention have been described. Nonethe ⁇ less, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiment, but only by the scope of the appended claims.

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Abstract

Procédé mettant en ÷uvre la méthode du chemin critique pour les tâches répétitives ayant des capacités productives constantes. Il permet à l'utilisateur d'élaborer un calendrier et d'assurer le suivi des tâches nécessaires à l'achèvement de travaux de taille importante et complexes, tout en minimisant la saisie de données, et en permettant l'actualisation en fonction de la progression réelle des travaux. On transforme les données destinées à une unité modèle en réseau de la méthode du chemin critique (CPM) adapté à l'ensemble des travaux, en déterminant les tâches répétitives (2) ainsi que leurs durées respectives et les rapports de priorité pour chaque unité supplémentaire impliquée dans les travaux. On prend également en compte les rapports de priorité entre les tâches identiques mais effectuées dans des unités différentes (1100-1145). Ces derniers rapports de priorité prennent en compte les déplacements des équipes dans les unités et/ou les déplacements des unités dans les postes de travail. On peut intégrer au réseau des limitations spéciales afin d'assurer aux équipes (1201-1213) un travail ininterrompu. On utilise le réseau CPM pour calculer les dates de démarrage et d'achèvement les plus avancées et les plus tardives possibles pour chaque tâche effectuée sur chaque unité (6). Le calendrier de planification se présente sous forme abrégée et facilement assimilée et constitue donc une amélioration par rapport aux diagrammes de Gantt traditionnels (7).
PCT/US1992/007504 1991-09-03 1992-09-03 Procede de planification de la capacite productive constante WO1993005476A1 (fr)

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US4019027A (en) * 1975-05-09 1977-04-19 Kelley William L Apparatus and method for schedule monitoring and control
US4700318A (en) * 1983-12-09 1987-10-13 Stuart Ockman Project construction with depiction means and methods
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CA2116982A1 (fr) 1993-03-18
EP0603326A4 (fr) 1995-04-05
EP0603326A1 (fr) 1994-06-29

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