The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The aspects of the illustrative embodiment, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
The illustrative embodiments provide for manufacturing optimization of complex solution delivery. With reference now to the figures and in particular with reference to
With reference now to the figures,
In the depicted example, server 104 and server 106 connect to network 102 along with storage unit 108. In addition, clients 110, 112, and 114 connect to network 102. These clients 110, 112, and 114 may be, for example, personal computers or network computers. In the depicted example, server 104 provides data, such as boot files, operating system images, and applications to clients 110, 112, and 114. Clients 110, 112, and 114 are clients to server 104 in this example. Network data processing system 100 may include additional servers, clients, and other devices not shown.
In the depicted example, network data processing system 100 is the Internet with network 102 representing a worldwide collection of networks and gateways that use the Transmission Control Protocol/Internet Protocol (TCP/IP) suite of protocols to communicate with one another. At the heart of the Internet is a backbone of high-speed data communication lines between major nodes or host computers, consisting of thousands of commercial, governmental, educational and other computer systems that route data and messages. Of course, network data processing system 100 also may be implemented as a number of different types of networks, such as for example, an intranet, a local area network (LAN), or a wide area network (WAN).
With reference now to
In the depicted example, data processing system 200 employs a hub architecture including a north bridge and memory controller hub (MCH) 202 and a south bridge and input/output (I/O) controller hub (ICH) 204. Processor 206, main memory 208, and graphics processor 210 are coupled to north bridge and memory controller hub 202. Graphics processor 210 may be coupled to the MCH through an accelerated graphics port (AGP), for example.
In the depicted example, local area network (LAN) adapter 212 is coupled to south bridge and I/O controller hub 204 and audio adapter 216, keyboard and mouse adapter 220, modem 222, read only memory (ROM) 224, universal serial bus (USB) ports and other communications ports 232, and PCI/PCIe devices 234 are coupled to south bridge and I/O controller hub 204 through bus 238, and hard disk drive (HDD) 226 and CD-ROM drive 230 are coupled to south bridge and I/O controller hub 204 through bus 240. PCI/PCIe devices may include, for example, Ethernet adapters, add-in cards, and PC cards for notebook computers. PCI uses a card bus controller, while PCIe does not. ROM 224 may be, for example, a flash binary input/output system (BIOS). Hard disk drive 226 and CD-ROM drive 230 may use, for example, an integrated drive electronics (IDE) or serial advanced technology attachment (SATA) interface. A super I/O (SIO) device 236 may be coupled to south bridge and I/O controller hub 204.
An operating system runs on processor 206 and coordinates and provides control of various components within data processing system 200 in
Instructions for the operating system, the object-oriented programming system, and applications or programs are located on storage devices, such as hard disk drive 226, and may be loaded into main memory 208 for execution by processor 206. The processes of the illustrative embodiments may be performed by processor 206 using computer implemented instructions, which may be located in a memory such as, for example, main memory 208, read only memory 224, or in one or more peripheral devices.
The hardware in
In some illustrative examples, data processing system 200 may be a personal digital assistant (PDA), which is generally configured with flash memory to provide non-volatile memory for storing operating system files and/or user-generated data. A bus system may be comprised of one or more buses, such as a system bus, an I/O bus and a PCI bus. Of course the bus system may be implemented using any type of communications fabric or architecture that provides for a transfer of data between different components or devices attached to the fabric or architecture. A communications unit may include one or more devices used to transmit and receive data, such as a modem or a network adapter. A memory may be, for example, main memory 208 or a cache such as found in north bridge and memory controller hub 202. A processing unit may include one or more processors or CPUs. The depicted examples in
The illustrative embodiments create the concept of a ship entity, which is comprised of groupings of multiple generic or customized products. Each of these customized or generic product groupings become a production order that is manufactured on a manufacturing line. These production orders or groups of products are referred to as build entities. The production for the set of production orders is configured to minimize work-in-progress. The start-to-build date/time schedule is customized for each build entity based on the ship entity schedule and the various product lead times in the manufacturing process. Some products may have lead times measured in hours as opposed to days, thus the illustrative embodiments allow for production orders to be released based on a time as well as a date. The release dates/times for the production orders are determined using the shipping entity for the order. This minimizes product wait time while still meeting customer requirements. The shipping entity has automated work direction to consolidate multiple build entities into a single shipment for the end customer. Build entity manufacturing is automatically triggered to start based on scheduled release offset dates/times or by the start of other build entities tied to the same ship entity.
The orders received from the customer may represent the total set of the products requested by the customer, the delivery date the customer wants the products, the location where the products are to be shipped, as well as other pertinent information. A “solution” to the customer's order represents the grouping of products that a customer wants to purchase together. A customer will typically define one or more ship-to addresses and may also define when products are desired to arrive at each ship-to location, i.e. a request date. Each logical grouping of products within the customer's order that must be built together as a single build entity and tested together in a single manufacturing plant is referred to as a build entity. A production order or build entity represents a single group of products that must be built/tested/managed together during the manufacturing process. From a manufacturing point of view, each build entity is a single production order. A single build entity must be started and completed as a unit within the manufacturing process. Each logical grouping of products in one or more build entities that must be shipped together from a single manufacturing plant to a single customer ship-to location and for a specified request date is referred to as a ship entity.
An exemplary order may be where a customer has a design for a new computer system for each of ten large stores. The order requires a computer rack with multiple customized servers installed in it as well as some displays, personal computers, and other equipment. The customer has an installation team that will be traveling to each store on a specific schedule to install and put the new systems into production. The customer requires that each order for each store is delivered based on this schedule. The solution results in ten ship entities that each have multiple required build entities. The manufacturing systems need to coordinate the production of the associated build entities within each ship entity. The manufacturing team will also have to communicate with the customer or sales representative if any part of the ship entity is delayed due to quality, rework, or parts shortages and determine if a partial shipment is desired.
Build entity determination module 304 determines which products must be built and/or tested together. Individual products are the lowest level of orderable product, such as a power cord, a shelf, or other single part item. Tied products are products that consist of numerous parts made on different manufacturing lines that require some type of assembly prior to shipping. Build entity determination module 304 assigns a build entity identifier to the product orders. The build entity identifier identifies which products are built together as a single production order and tested together in a single manufacturing plant. Build entity determination module 304 then sends the order information with the build entity identifiers to ship entity determination module 306.
Ship entity determination module 306 uses the build entity information from build entity determination module 304 along with the information in the order to determine which products will be required to be shipped together and assigns ship entity identifiers to the individual product orders. The ship entity information is sent to production scheduling module 308. Production scheduling module 308 uses the order information, build entity information, and ship entity information to produce and assign build entities/production orders to the appropriate manufacturing lines with start to build dates/times, also referred to as release dates/times, based on known production lead times such that all production orders in the ship entity will complete at the same time and on the required date for common shipment. Production scheduling module 308 uses estimated timelines associated with the manufacturing of each product to create a production schedule. The production orders are configured to release on specific dates/times, so that work-in-progress is minimized. That is, completed products are not waiting around for other products to be manufactured in order for the entire shipment to be shipped at a single time. Each of the production orders are synchronized with the determined production schedule.
The production orders are stored and sent to the required production execution modules 310 once a release date/time is encountered. Each of production execution modules 310 represent a manufacturing plant or build entity where the products are built. Thus, each product, individual or tied, has an associated build entity. The manufacturing plants use their respective production execution modules 310 to determine the production orders they are required to build. Then the manufacturing plant manufactures the product(s) per the production order. Each manufacturing plant then updates its respective production execution modules 310 as to the status of the build entity. Once the product or build entity is complete, it is shipped to a shipping facility and an associated shipping module 312 is updated that the product has been sent.
The shipping facility uses shipping module 312 to ensure receipt of each completed build entity from the various manufacturing lines. Shipping module 312 prepares entire ship entity as a single shipment, such as preparing labels, paperwork, interfaces to transportation vendors, etc. The shipping facility has automated work direction to consolidate multiple build entities into a single shipment for the end customer.
Production scheduling module 308 constantly monitors the timelines associated with each product and/or part. If a timeline is changed at any point during manufacturing or prior to a production order being sent to the appropriate production execution modules 310, production scheduling module 308 is able to modify any pending production orders to minimize the number or products that will have to be temporarily stored at the shipping facility. If a delay is encountered during manufacturing, production scheduling module 308 notifies shipping module 312 of the delay and estimated time of delay. Although only one shipping module is shown, there may be many shipping modules representing regional ship locations.
Thus, the optimization of releasing production orders to manufacturing plants only when a release date/time is encountered, decreases the amount of products waiting at a shipping facility for other products that are still being manufactured.
A ship entity determination module, such as ship entity determination module 306 of
As shown in
During the end of testing of build entities 408 and 410, production orders for single products 414 and 434 are released to the manufacturing plant responsible for build entities 406 and 412 in order that the time to pick and pack these individual products will be approximately the time that testing at build entities 408 and 410 complete testing of single products 416, 418, 420, 422, 424, 426, 428, 430, and 432. Thus, the single products provided by build entities 406 and 408 are estimated to arrive at the shipping facility at approximately the same time so that ship entity 402 may ship together and no products require temporary storage. Also, the single products provided by build entities 410 and 412 are estimated to arrive at the shipping facility at approximately the same time so that ship entity 404 may ship together and no products require temporary storage.
If the status update is a timeline change, the production scheduling module determines whether all production orders related to a specific ship entity have been released (step 812). If there are pending production orders that have not been release, production scheduling module updates the release date/time of those production orders and notifies the ship entity that a delay has been encountered (step 814). The notification to the ship entity provides a warning that part of a ship entity may need to be temporarily stored. If at step 812, all production orders have been released, the production scheduling module notifies the ship entity of the encountered delay (step 816) with the operation continuing to step 818. If at step 810, the status update is not a time line change, the production scheduling module waits for a status that the production order has completed (step 818).
Once all production orders related to a specific ship entity have completed, the ship entity is prepared as a single shipment and shipped (step 820). Once the ship entity ships, the operation terminates. If production orders associated with a ship entity are still pending, the operation returns to step 808.
Thus, the illustrative embodiments receive an order for processing and the order contains a plurality of products. A set of build entities are formed from the order and each build entity in the set of build entities corresponds to one or more products in the plurality of products. The illustrative embodiments create a set of production orders for the set of build entities. Release dates/times for the set of production orders are formed using a shipping entity for the order and production for the set of production orders is optimized to minimize work-in-progress.
The invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the invention is implemented in software, which includes but is not limited to firmware, resident software, microcode, etc.
Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer readable medium can be any tangible apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W) and DVD.
A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution.
Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers.
Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.