WO2019120341A1

WO2019120341A1 - Production monitoring system

Info

Publication number: WO2019120341A1
Application number: PCT/DE2017/000371
Authority: WO
Inventors: Jens MONSER; Nina MONSER
Original assignee: Monser Jens; Monser Nina
Priority date: 2017-12-21
Filing date: 2017-12-21
Publication date: 2019-06-27
Also published as: DE112017008177A5

Abstract

Industry is not interlinked in such a way that scarce global resources, whether material or human, can be used intelligently and sensibly. This program combines all necessary resources and the possessors thereof in order make production so efficient that materials are utilized to the highest possible degree and loss of production is almost completely avoided. In this way, it is also possible to efficiently plan the manpower, to avoid overtime, to improve work-life balance, and to control the general output nearly ideally. The burden on the environment is also reduced, because empty trips and partial capacity utilization are avoided in logistics and the waste of resources is reduced. Every production across multiple factories can be controlled as if it occurred in one factory. The flow of information and the workflow are optimized to a point where the predictability of the individual planning points makes an unpredictable result also impossible. Industry 5.0 uses the achievements of digitalization to make production and manpower nearly 100% controllable.

Description

PRODUCTION MONITORING SYSTEM

Basic problem:

The industry supply chain is too complex to anticipate disruptions without the help of an intelligent control program.

Benefit of the program:

Zeck's predictive algorithms, which are fed with the existing production data and compare it with marginal parameters and experience, create a prediction of parts availability that enables the end of the supply chain

To create production flexibility that virtually eliminates disruption and maximizes profit.

Functionality:

First of all, the program must be able to receive the output of the various tools in a single language, and so on one data

Capture platform and relate to each other. In principle, the program cross-site creates a virtual factory that captures every single part (independent of the production site) and forwards its data (hourly recording of production output) to the virtual factory. The virtual factory is equipped with parameters that represent ideal production of the components. Due to the ideal state and the constant input, the program is capable of using prediction algorithms disruptions

anticipate. In addition, it captures the dynamic inventory and can thereby make the lines of final production fully flexible to offset the effects of shortage production along the supply chain. Furthermore, a subapplication can track the GPS data of deliveries and match it with traffic information. Thus, predictions for the arrival of deliveries can be made. Another subapplication records the utilization of logistics in order to anticipate possible disruptions that may result. It is possible at every critical point of the supply chain not only to detect any damage, but also to determine its extent and corresponding

Take countermeasures to reduce the financial loss.

As a further component, measures for quality assurance (sorting, cleaning, reworking) can be included here. If these are tracked in real time, one can also determine the effects on production here. Shared data from the human resources department would even allow tailor-made planning for disease or strike waves. State of the art:

Currently, so-called performance management cockpits dominate the market. The functioning of these cockpits is limited to the collection and processing of the data of a factory / factory / manufacturer. These data are more or less completely related to each other in order to

To visualize and ideally evaluate energy-related or economic KPIs (Key Performance Indicators) in real time over the entire selected dimension. In some solutions this is only possible by production line or production department, in others

Solutions can map almost the entire production of a location. The already existing in the system, but heterogeneous data, on a time and

inexpensive type bundled and processed. Without such an application, this process is so lengthy that its optimization potential is low, since the data is already outdated when the result is provided. Another individualization of

Programs allows a specific view per user. A plant manager needs an overview of the production lines, which offers no further details, whereas the line master needs every detail of his line in the view. Plant and department managers see who is responsible for a problem, the person in charge sees for himself where the problem arises and can fix it. In addition, the common performance management cockpits have universal interfaces for connecting third-party applications, an intuitive user interface, a location-independent access (cloud system) and a strong analytical application in the background, optimally consisting of an in-memory database, the can process larger amounts of data with high performance. Systems of this kind are offered for example by large software manufacturers. The analysis of tool performance or wear is mostly done by the

Tool manufacturers in the form of their own systems included.

Another way of using collected data is by some OEMs themselves. Here, data of the individual plants or plant associations are bundled and analyzed accordingly. However, this analysis does not go beyond the own production and does not include the data of the suppliers of the individual processed parts and components. Operation of the system

Based on the state of the art, the system is an innovative advancement that combines existing components to create a new value. A complex end product is indeed produced within a plant, the individual

However, components or parts come from tens of different works. Even an OEM with a high own vertical range of manufacture at e.g. Engines or gearboxes often use several production sites in their plant network to manufacture the individual components. In addition, there is a large number of delivered parts. The sheer number of production sites of the individual parts and components for a car makes it almost impossible to react promptly to impassability. A major German OEM recently felt this, as in the supply chain of Tier 1 a part of the day was not available in good quality. The OEM's production lines were shut down at several global locations. Fully flexible production, which more and more OEMs favor and successively introduce, would be able to avoid such a situation with suitable early warning systems and corresponding planning tools. This is where our system comes in. The system makes it possible to create a virtual factory, regardless of location or supplier, that captures every part and component of any end product and collects its data. The system will start with the desired parameters

Ideal production per part, component and end product equipped. As a result, the system automatically calculates the maximum output of the virtual factory. This is regularly compared with the actual needs of the final producer. If this differs positively from the maximum output size, the final producer can define a parameter for an estimated demand and produce a buffer on this basis. If it deviates negatively, the end producer must analyze with the system whether he has the

Eliminate production downtime through an estimated need of other end products, thus producing a buffer for this. This assessment is made with another size determined by the system, the estimated maximum output. This size is determined by the maximum capacity of their production reported by all parties involved. This maximum capacity is only for exceptional cases and not for continuous operation and intended for balancing activities. logistics management

Logistics is not only an essential part of the value chain, but also highly complex. At this moment it is not possible, beyond a certain degree, to optimize delivery and costs. There are basically two aspects to consider: 1. The predictability of deliveries and their impact on production; and 2. The intelligent planning of deliveries and the avoidance of empty runs or unused space. Planability can already be optimized today by recording the status of the delivery at each station by scan (place of production / transhipment point / warehouse / destination). With the system and a link to the current traffic data, it is possible to anticipate delays of more than half an hour and report them to the destination. This increases the predictability of production, which is about the

Can bring lunch break forward to bridge a time without parts. The system alerts the person responsible at the destination when an unforeseeable event (full closure, unusually high traffic volume) delays the delivery. The second aspect requires two things: Firstly, there must be free in the system

Supply capacity or partial capacity utilization are reported to the market, and secondly, suppliers without their own fleet have to fall back on the market. The system makes it possible to summarize planned deliveries that do not make sense to trucks in terms of distance and volume and thus to share the delivery costs (shared delivery). On the one hand, this offers a cost reduction and an ideal use of human resources. On the other hand, it facilitates the spontaneous acceptance of forwarding orders with otherwise no or too low utilization (for example, cost-consuming empty trips). Shared Delivery also offers the opportunity to plan delivery vehicles better and more efficiently through the use of controlled and sensible delivery routes. Also, the use of smaller delivery vans for part routes, groupage transport and the use of

Transshipment points is possible.

To Fig. 1:

The system distinguishes between 3 types of links. It knows that

Internal demand links (site-internal), links for production needs (fixed set of allowed interfaces within the virtual factory) and the

Links to the market, which must be released separately for individual items. In the latter case, the output is visible to all market participants (possibly also via external search engine service). The own production reports in one direction data about the system to the end A / Veiterverarbeitung. From the market and from the

Subcontractors receive their own production data. The constellation means that data security is guaranteed at all times. Because every transfer of data takes place only with explicit release and always via the system as a stopover. In addition, the system simultaneously manages two fundamentally different areas: the planned and the spontaneous business. The planned business is based on firm agreements and a certain amount of partners. It is the normal core business that can be planned almost 100% through the connection in the system and is always controllable and customizable. The spontaneous business is the exact opposite. Since every participant can enter into a spontaneous and temporary connection with every other participant, this business can not be planned, it can only be controlled. It's dynamic, it promotes new ones

Business relations and prevent the waste of capacity and

Resources.

To Fig. 2:

The chaos-led storage system of the worldwide resources of the companies belonging to the Monser system enables an intelligent distribution of resources (processing including logistics managed by the system). First, one differentiates between ordered products and overproduction. The ordered products follow a predictable, regular process between the manufacturers, logistics companies and the final production. All processes are recorded in the system so that unplanned disruptions are immediately communicated to all involved. This allows productions along the supply chain to be planned alternatively. This reduces downtime and losses. The processes of overproduction also run through the system. Here are 2 essential components recorded and controlled:

Resources that are no longer needed and loading space in not fully loaded delivery vehicles. The overproduction / under-utilization can be offered in the market of the system. There it is available for every participant. In the market, goods can be sold in all directions. From manufacturer to manufacturer, from manufacturer to

Final production, but also from the final production to the manufacturer. This overproduction may be commodity whose market price is changing rapidly, such as aluminum, where too long storage may mean a loss to raw materials like

Cotton, which can spoil by too long or wrong storage. In addition, free loading capacities or entire means of transport can be offered or rent via the market. For example, if manufacturer 2 owns a truck that he does not currently use, manufacturer 3, who does not own one, can rent it through the market and use it at times. It would also be possible for manufacturer 2 to use the truck only partially and manufacturer 1 (excluding trucks) with the remaining available cargo area on a) the same route, b) a part of the same route and destination on the originally planned route or c) one Leg starting with the originally planned route and the same destination; or d) a leg where the start and finish lie within the planned route. Another option is to pick up goods at transhipment points or transshipment points. It is also conceivable that a normally planned empty journey is rented cost-reducing or cost-covering to another manufacturer. After a settling-in period, it is also conceivable that manufacturers who deliver on the same days to the same final production and whose routes offer themselves for this, jointly deliver in the future in order to reduce costs. Views / subscriptions

The system is purchased in the basic version, which optimizes production planning and control. This version is purchased per site and has as many accesses as needed within that location. The secured system has a secure

Interface for data exchange with the other participants of the virtual factory.

Additional options that enable logistics or resource management in the market have to be paid additionally. Each retrieval of a service / goods from the market costs a fee. The provision of services / goods is free of charge. It is possible to subscribe to offers of certain services / goods. In that case, the Subscriber will receive an email notification for each new offer that is being posted. There is a fee per subscription for this service. However, the fee per call will be waived if the call is made from one of the subscribed offers.

Resource Management:

Similar to the intelligent management of logistics operations, the system can also provide intelligent resource management. Again, the basis is the placement of supply / demand in the market of the system.

To illustrate this application with an example: Supplier A has produced out of turn because of a good opportunity. The resource used cotton is still available in some quantity. Since the temporary production change has come to an end and the resource cotton is no longer needed, supplier A wants to sell the cotton as long as the quality has not suffered from too long storage. Supplier A puts the cotton in the market of the system. Every supplier who regularly processes cotton now has the opportunity to buy the resource directly. If neither supplier A nor the buyer has immediate transportation, the logistics management of the system can solve this problem. Existing resources are optimally used by the possibilities of the system, over-stocks are avoided and storage places for more important resources free.

The resource management also offers the management and offering of production capacities. In the case of an unscheduled shortfall, the free production capacity can be circumscribed and offered through the market. The advantage for medium-sized companies and micro-enterprises is another way to compensate for under-utilization in the event of a bad order situation. The advantage for end producers is that unpredictable events cut them off from the flow of goods of a planned and secured part. A fire in a forge, for example, can cause a headache for an OEM if the part made there is not available for the foreseeable future. Here, several smaller blacksmiths can cross the market

merge together and collect the required capacity for the OEM. For medium-sized companies or highly specialized micro-enterprises, this also gives them the opportunity to secure follow-up orders with good performance.

Claims

Claims:

1) Entitled to a performance cockpit system capable of monitoring and controlling the entire production across sites and producers (Virtual Factory). For this purpose, a Performance Cockpit application is extended to use prediction algorithms and predefined parameters to determine predictive statements about the shift or daily performance and their impact on subsequent production steps and to report this to all relevant participants of the "virtual factory". In addition, the system is capable of using the

Collected data and stored parameters to cope with a reduced production by appropriately adjusted utilization of the follow-up lines and thereby minimize the damage.

2) entitled to a market embedded in this system, which allows the

Intelligently and quickly redistribute production or raw material surplus of your own factory. The market is based on a purely offer function, which can be bought bilaterally.

3) eligible for a market embedded in this system, the

Intelligently manages logistics services and makes it possible to partially or completely avoid empty runs by connecting users without logistics components with users who offer space on vehicles or entire vehicles. Here, too, the background system collects data that it compares with predefined parameters. It determines how the load of each vehicle was planned on the routes and there is an option still available

Transport place to offer accurately. As with the production or raw materials market, this market also operates on a pure supply area, which enables a bilateral settlement of the purchase.