Optimized parts pickup list and routes for efficient manufacturing using frequent pattern mining and visualization

A non-transitory computer readable medium storing instructions for executing a process, the instructions comprising:

• executing item ordering for a plurality of lots and route optimization for each of a plurality of workers on a manufacturing floor, the manufacturing floor comprising a plurality of items disposed amongst a plurality of racks, wherein each lot of the plurality of lots comprises an itemset of the plurality of items;
• determining rack placement of the plurality of racks and total travel distance for the each of the plurality of workers;
• determining frequent patterns sets indicating items of the plurality of items more likely to be included in a respective itemset of the plurality of lots than other items of the plurality of items;
• determining individual item frequencies within the plurality of racks and individual item priority within the plurality of racks;
• generating a rack filling plan for item placement amongst the plurality of racks based on frequent patterns sets, individual item frequencies and priority within racks;
• generating a deployment plan for the each of the plurality of workers from the item ordering, the route optimization, the rack placement, the rack filling plan, avoidance of collision/congestion between the plurality of workers, and the total travel distance, the deployment plan comprising an order list of pick-up items for each lot, an optimized route, and a schedule for the each of the plurality of workers;
• providing the deployment plan to an interface configured to receive modifications to the deployment plan;
• upon receiving instructions to deploy the deployment plan through the interface, providing the deployment plan to a device of each of the plurality of workers;
• receiving feedback data of the plurality of lots from the device of each of the plurality of workers based, in part, on executing the deployment plan;
• generating a visualization for display with the interface based on the deployment plan by:
• displaying floor map of the manufacturing floor in a first region of the visualization, the floor map comprising the plurality of racks having the plurality of items disposed therein;
• displaying, in the first region, a visualization of aggregated trajectories of the plurality of workers on the floor map according to a first color scheme that assigns segments of the aggregated trajectories different colors based on a frequency of the plurality of workers in each respective segment;
• and
• while the plurality of workers execute each deployment plan:
• receiving an input in the first region selecting at least one of the segments on the floor map to be blocked, and
• in response to receiving the input, updating the item ordering, the route optimization, the rack placement, and the total travel distance for each of the plurality of workers to avoid the selected at least one of the segments and automatically re-generating the deployment plan based on the updates to the item ordering, the route optimization, the rack placement, and the total travel distance,
• wherein the frequent patterns sets are derived from historical data of the plurality of lots received from a database intaking the feedback data from the device of each of the plurality of workers.

A management system, comprising:

• a processor, configured to:
• execute item ordering for a plurality of lots and route optimization for each of a plurality of workers on a manufacturing floor, the manufacturing floor comprising a plurality of items disposed amongst a plurality of racks, wherein each lot of the plurality of lots comprises an itemset of the plurality of items;
• determine rack placement of the plurality of racks and total travel distance for the each of the plurality of workers;
• determine frequent patterns sets indicating items of the plurality of items more likely to be included in a respective itemset of the plurality of lots than other items of the plurality of items;
• determine individual item frequencies within the plurality of racks and individual item priority within the plurality of racks;
• generate a rack filling plan for item placement amongst the plurality of racks based on frequent patterns sets, individual item frequencies and priority within racks;
• generate a deployment plan for the each of the plurality of workers from the lot item ordering, the route optimization, the rack placement, the rack filling plan, avoidance of collision/congestion between the plurality of workers, and the total travel distance, the deployment plan comprising an order list of pick-up items for each lot, an optimized route, and a schedule for the each of the plurality of workers;
• provide the deployment plan to an interface configured to receive modifications to the deployment plan;
• upon receiving instructions to deploy the deployment plan through the interface, provide the deployment plan to a device of each of the plurality of workers;
• receive feedback data of the plurality of lots from the device of each of the plurality of workers based, in part, on executing the deployment plan;
• generate a visualization for display with the interface based on the deployment plan by:
• displaying floor map of the manufacturing floor in a first region of the visualization, the floor map comprising the plurality of racks having the plurality of items disposed therein;
• displaying, in the first region, a visualization of aggregated trajectories of the plurality of workers on the floor map according to a first color scheme that assigns segments of the aggregated trajectories different colors based on a frequency of the plurality of workers in each respective segment;
• and
• while the plurality of workers execute each deployment plan:
• receive an input in the first region selecting at least one of the segments on the floor map to be blocked, and
• in response to receiving the input, update the item ordering, the route optimization, the rack placement, and the total travel distance for each of the plurality of workers to avoid the selected at least one of the segments and automatically re-generate the deployment plan based on the updates to the item ordering, the route optimization, the rack placement, and the total travel distance,
• wherein the frequent patterns sets are derived from historical data of the plurality of lots received from a database intaking the feedback data from the device of each of the plurality of workers.