Method, data processing device, and system for adaptive control of complex production chains

In a production system for processing products having a desired-value memory and a series of production stations, each of the production stations having a buffer, a respective machine performing a respective step to produce a respective intermediate product and having a respective buffer time stored in the desired-value memory, at least one of the machines continuing to operate throughout a failure of one of the machines of a preceding production step by processing a stock of intermediate products corresponding to the associated buffer time and stored in the buffer during production;

• a data processing device automatically optimizing the buffer times, comprising:
• a data server storing data selected from the group consisting of production data and fault event data;
• a production database;
• a mean-time-to-repair (MTTR) database;
• a production data acquisition device connected to said data server and said production database, accessing the data in said data server, having a data input for receiving additional fault event data, registering stoppage times of the machines, and storing the stoppage times of the machines in said production database;
• an MTTR calculator connected to said production database and said MTTR database, accessing said production database, calculating MTTR characteristic values from the stoppage times, and storing the MTTR characteristic values in said MTTR database;
• and
• a buffer-time (TP) calculator connected to said MTTR database and the desired-value memory, accessing said MTTR database, calculating the buffer times from the MTTR characteristic values using an assessment model, and storing the buffer times in said desired-value memory.

A production system for processing products, comprising:

• a buffer;
• a desired-value memory;
• a series of production stations, each of said production stations having a respective machine performing a respective step to produce a respective intermediate product and having a respective buffer time stored in said desired-value memory, at least one of said machines continuing to operate throughout a failure of one of the machines of a preceding production step by processing a stock of intermediate products corresponding to an associated buffer time and stored in said buffer during production;
• and
• a data processing device automatically optimizing the buffer times, including:
• a data server storing data selected from the group consisting of production data and fault event data;
• a production database;
• a mean-time-to-repair (MTTR) database;
• a production data acquisition device connected to said data server and said production database, accessing the data in said data server, having a data input for receiving additional fault event data, registering stoppage times of said machines, and storing the stoppage times of said machines in said production database;
• a mean-time-to-repair (MTTR) calculator connected to said production database and said MTTR database, accessing said production database, calculating MTTR characteristic values from the stoppage times, and storing the MTTR characteristic values in said MTTR database;
• and
• a buffer-time (TP) calculator connection to said MTTR database and said desired-value memory, accessing said MTTR database, calculating the buffer times from the MTTR characteristic values using an assessment model, and storing the buffer times in said desired-value memory.