US 6,865,432 B2Granted

Optimization of manufacturing equipment capacities in a batch manufacturing process

OwnerPeter G. Browninventor

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Abstract

In an effort to achieve the lowest cost of goods (COG) possible, a key objective in batch manufacturing is to maximize equipment utilization so that the capacity and size of equipment per batch cycle is the smallest possible for a given batch production capacity. This optimization of equipment utilization minimizes equipment and direct utility costs per batch, as well as reduces the physical space and the associated utilities required to support manufacturing operations. The present invention provides a process of: (1) determining the optimal number of batch cycles per year for a required annual production capacity; and (2) determining the optimal number of equipment cycle iterations per batch cycle in a manner that: (a) creates the smallest batch sizes possible; and (b) achieves higher equipment utilization per batch cycle, thereby reducing the capacity and size of equipment required to produce a given batch quantity of product.

Claims2

Dependent claims

A method for optimizing equipment utilization and capacity within a batch manufacturing facility, comprising:

(1) determining a unit operation sequence for production of a product, wherein said unit operation sequence is a series of unit operations that are required to produce said product;
(2) determining an associated duration for each unit operation in said unit operation sequence;
(3) determining the longest unit operation duration (UODmax) among said unit operations forming said unit operation sequence;
(4) setting a batch cycle offset (BCO) parameter equal to UODmax;
(5) determining a maximum length of time said product can be held at any given unit operation before completing said given unit operation;
(6) if said BCO is less than or equal to said maximum length of time for a given unit operation, then the number of unit operation cycles for that unit operation is increased until a cumulative duration of these multiple unit operation cycles (UODcum) is as close to said BCO as possible without exceeding said BCO;
and
(7) If said BCO is greater than said maximum length of time for a given unit operation then the number of unit operation cycles for that unit operation is increased until UODcum is as close as said maximum length of time as possible without exceeding said maximum length of time.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 10/152,348Filed 22 May 2002 · us provisional application
Priority: 22 May 2001
Published: US 2003/0033045 A113 Feb 2003
Granted: 8 Mar 2005
Term ends: Not estimatedThe source records don’t support an estimate.

Classification9 codes

G06Q 10/04
Administration; Management: forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or…
G05B 19/41865
Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible…:…
G05B 2219/32283
Operator till task planning: machine scheduling, several machines, several jobs
G05B 2219/32293
Operator till task planning: minimize work in progress, system at maximum productivity