Dynamic-state waiting time analysis method for complex discrete manufacturing

1. A method of analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the method comprising:

determining stochastic parameters for each task of said plurality of tasks;

calculating a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

providing the calculated stochastic waiting time as an input to a production planning system;

wherein the stochastic parameters determined for each task include all of the following:

(a) priority relative to other tasks;

(b) processing time;

(c) expected end time;

(d) relative slack time;

(e) task due date;

(g) expected earliest start time; and

(h) lead time.

2. A method according to claim 1 , wherein the stochastic waiting time for said at least one selected task is calculated based at least in part on:

(a) the determined stochastic parameters for said at least one selected task; and

(b) the determined stochastic parameters for each other one of said tasks that potentially conflicts with said at least one selected task.

3. A method according to claim 1 , wherein at least some of the manufacturing resources are machine tools.

4. A method according to claim 1 , further comprising:

adjusting a stochastic expected start time parameter for said at least one selected task and a stochastic expected end time parameter for said at least one selected task based at least in part on the calculated stochastic waiting time.

5. A method according to claim 4 , further comprising:

setting a stochastic expected earliest start time parameter of at least one successor task of said at least one selected task in accordance with said adjusted stochastic expected end time parameter fix said at least one selected task.

6. A method of analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the method comprising:

determining stochastic parameters for each task of said plurality of tasks;

calculating a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

providing the calculated stochastic waiting time as an input to a production planning system;

wherein the stochastic waiting time for said at least one selected task is calculated based at least in part on:

(a) the determined stochastic parameters for said at least one selected task; and

(b) the determined stochastic parameters for each other one of said tasks that potentially conflicts with said at least one selected task;

wherein said calculating a stochastic waiting time for said at least one selected task includes:

determining a competing task set that includes all tasks that potentially conflict with said at least one selected task;

calculating, based at least in part on said determined stochastic parameters, a stochastic priority parameter for said at least one selected task and for each task included in said competing task set;

initially setting to zero each of a minimum value, a most likely value, and a maximum value of a stochastic waiting time for said at least one selected task;

performing a resource loop with respect to each manufacturing resource allocated to said at least one selected task, said resource loop including:

initially setting to zero each of a minimum, value, a most likely value and a maximum value of a stochastic waiting time for said at least one selected task relative to said each manufacturing resource allocated to said at least one selected task;

performing a competing task loop with respect to each task included in said competing task set, said competing task loop including:

if a maximum value of the stochastic priority parameter of said each task included in said competing task set is greater than a minimum value of the stochastic priority parameter of said at least one selected task for which the stochastic waiting time is being calculated:

calculating an overlap time relative to said each task included in said competing task set and said at least one selected task for which the stochastic waiting time is being calculated; and

increasing said maximum value of said stochastic waiting time relative to said each manufacturing resource allocated to said at least one selected task for which the stochastic waiting time is being calculated, said increasing by an amount equal to a product formed by multiplying said overlap time by a likelihood that said each manufacturing resource is to be used by said each task included in said set of competing tasks;

if a most likely value of the stochastic priority parameter of said each task included in said competing task set is greater than a most likely value of the stochastic priority parameter of said at least one selected task for which the stochastic waiting time is being calculated, increasing by said product said most likely value of said stochastic waiting time relative to said each manufacturing resource; and

if a minimum value of the stochastic priority parameter of said each task included in said competing task set is greater than a maximum value of the stochastic priority parameter of said at least one selected task for which the stochastic waiting time is being calculated, increasing by said product said minimum value of said stochastic waiting time relative to said each manufacturing resource;

said resource loop further including:

increasing said maximum value of said stochastic waiting time that is being calculated by an amount equal to a product formed by multiplying said maximum value of said stochastic waiting time relative to said each manufacturing resource by a likelihood that said each manufacturing resource is to be used by said at least one selected task for which said stochastic waiting time is being calculated;

increasing said most likely value of said stochastic waiting time that is being calculated by an amount equal to a product formed by multiplying said most likely value of said stochastic waiting time relative to said each manufacturing resource by a likelihood that said each manufacturing resource is to be used by said at least one selected task for which said stochastic waiting time is being calculated; and

increasing said minimum value of said stochastic waiting time that is being calculated by an amount equal to a product formed by multiplying said minimum value of said stochastic waiting time relative to said each manufacturing resource by a likelihood that said each manufacturing resource is to be used by said at least one selected task for which said stochastic waiting time is being calculated.

7. A method of analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the method comprising:

determining stochastic parameters for each task of said plurality of tasks;

calculating a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

providing the calculated stochastic waiting time as an input to a production planning system;

wherein the calculated stochastic waiting time for said at least one selected task is expressed as a probability density function supported in a range between a first end point that represents a minimum waiting time and a second end point that represents a maximum waiting time, said probability density function exhibiting a peak value that represents a most likely waiting time.

8. A method according to claim 7 , wherein the probability density function is a triangular probability density function.

9. A method according to claim 7 , wherein the probability density function is a beta probability density function.

10. A method of analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the method comprising:

determining stochastic parameters for each task of said plurality of tasks; and

calculating a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

providing the calculated stochastic waiting time as an input to a production planning system;

wherein each of the stochastic parameters is expressed as a probability density function supported in a range between a first end point that represents a minimum value of the parameter and a second end point that represents a maximum value of the parameter, said probability density function exhibiting a peak value that represents a most likely value of the parameter.

11. A method according to claim 10 , wherein the probability density function is a triangular probability density function.

12. A method according to claim 10 , wherein the probability density function is a beta probability density function.

13. An apparatus for analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the apparatus comprising:

a processor; and

a memory coupled to the processor and storing software instructions, said processor operative with said software instructions to:

determine stochastic parameters for each task of said plurality of tasks;

calculate a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

provide the calculated stochastic waiting time as an input to a production planning system;

wherein the stochastic parameters determined for each task include all of the following:

(a) priority relative to other tasks;

(b) processing time;

(c) expected end time;

(d) relative slack time;

(e) task due date;

(g) expected earliest start time; and

(h) lead time.

14. An apparatus according to claim 13 , wherein the stochastic waiting time for said at least one selected task is calculated based at least in part on:

(a) the determined stochastic parameters for said at least one selected task; and

(b) the determined stochastic parameters for each other one of said tasks that potentially conflicts with said at least one selected task.

15. An apparatus according to claim 13 , wherein the processor is further operative with the software instructions to:

adjust a stochastic expected start time parameter for said at least one selected task and a stochastic expected end time parameter for said at least one selected task based at least in part on the calculated stochastic waiting time.

16. An apparatus according to claim 15 , wherein the processor is further operative with the software instructions to:

set a stochastic expected earliest start time parameter of at least one successor task of said at least one selected task in accordance with said adjusted stochastic expected end time parameter for said at least one selected task.

17. An apparatus for analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the apparatus comprising:

a processor; and

a memory coupled to the processor and storing software instructions, said processor operative with said software instructions to:

determine stochastic parameters for each task of said plurality of tasks;

calculate a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

provide the calculated stochastic waiting time as an input to a production planning system;

wherein the stochastic waiting time for said at least one selected task is calculated based at least in part on:

(a) the determined stochastic parameters for said at least one selected task; and

(b) the determined stochastic parameters for each other one of said tasks that potentially conflicts with said at least one selected task;

wherein the processor calculates said stochastic waiting time for said at least one selected task of said plurality of tasks by:

determining a competing task set that includes all tasks that potentially conflict with said at least one selected task;

calculating, based at least in part on said determined stochastic parameters, a stochastic priority parameter for said at least one selected task and for each task included in said competing task set;

initially setting to zero each of a minimum value, a most likely value, and a maximum value of a stochastic waiting time for said at least one selected task;

performing a resource loop with respect to each manufacturing resource allocated to said at least one selected task, said resource loop including:

initially setting to zero each of a minimum value, a moat likely value and a maximum value of a stochastic waiting time for said at least one selected task relative to said each manufacturing resource allocated to said at least one selected task;

performing a competing task loop with respect to each task included in said competing task set, said competing task loop including:

if a maximum value of the stochastic priority parameter of said each task included in said competing task set is greater than a minimum value of the stochastic priority parameter of said at least one selected task for which the stochastic waiting time is being calculated:

calculating an overlap time relative to said each task included in said competing task set and said at least one selected task for which the stochastic waiting time is being calculated; and

increasing said maximum value of said stochastic waiting time relative to said each manufacturing resource allocated to said at least one selected task for which the stochastic waiting time is being calculated, said increasing by an amount equal to a product formed by multiplying said overlap time by a likelihood that said each manufacturing resource is to be used by said each task included in said set of competing tasks;

if a most likely value of the stochastic priority parameter of said each task included in said competing task set is greater than a most likely value of the stochastic priority parameter of said at least one selected task for which the stochastic waiting time is being calculated, increasing by said product said most likely value of said stochastic waiting time relative to said each manufacturing resource; and

if a minimum value of the stochastic priority parameter of said each task included in said competing task set is greater than a maximum value of the stochastic priority parameter of said at least one selected task for which the stochastic waiting time is being calculated, increasing by said product said minimum value of said stochastic waiting time relative to said each manufacturing resource;

said resource loop further including:

increasing said maximum value of said stochastic waiting time that is being calculated by an amount equal to a product formed by multiplying said maximum value of said stochastic waiting time relative to said each manufacturing resource by a likelihood that said each manufacturing resource is to be used by said at least one selected task for which said stochastic waiting time is being calculated;

increasing said most likely value of said stochastic waiting time that is being calculated by an amount equal to a product formed by multiplying said most likely value of said stochastic waiting time relative to said each manufacturing resource by a likelihood that said each manufacturing resource is to be used by said at least one selected task for which said stochastic waiting time is being calculated; and

increasing said minimum value of said stochastic waiting time that is being calculated by an amount equal to a product formed by multiplying said minimum value of said stochastic waiting time relative to said each manufacturing resource by a likelihood that said each manufacturing resource is to be used by said at least one selected task for which said stochastic waiting time is being calculated.

18. An apparatus for analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the apparatus comprising:

a processor; and

a memory coupled to the processor and storing software instructions, said processor operative with said software instructions to:

determine stochastic parameters for each task of said plurality of tasks;

calculate a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

provide the calculated stochastic waiting time as an input to a production planning system;

wherein the calculated stochastic waiting time for said at least one selected task is expressed as a probability density function supported in a range between a first end point that represents a minimum waiting time and a second end point that represents a maximum waiting time, said probability density function exhibiting a peak value that represents a most likely waiting time.

19. An apparatus according to claim 18 , wherein the probability density function is a triangular probability density function.

20. An apparatus according to claim 18 , wherein the probability density function is a beta probability density function.

21. An apparatus for analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the apparatus comprising:

a processor; and

a memory coupled to the processor and storing software instructions, said processor operative with said software instructions to:

determine stochastic parameters for each task of said plurality of tasks;

calculate a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

provide the calculated stochastic waiting time as an input to a production planning system;

wherein each of the stochastic parameters is expressed as a probability density function supported in a range between a first end point that represents a minimum value of the parameter and a second end point that represents a maximum value of the parameter, said probability density function exhibiting a peak value that represents a most likely value of the parameter.

22. An apparatus according to claim 21 , wherein the probability density function is a triangular probability density function.

23. An apparatus according to claim 21 , wherein the probability density function is a beta probability density function.

24. An apparatus for analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the apparatus comprising:

means for determining stochastic parameters for each task of said plurality of tasks;

means for calculating a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

means for providing the calculated stochastic waiting time as an input to a production planning system;

wherein the calculated stochastic waiting time for said at least one selected task is expressed as a probability density function supported in a range between a first end point that represents a minimum waiting time and a second end point that represents a maximum waiting time, said probability density function exhibiting a peak value that represents a most likely waiting time.

25. An apparatus according to claim 24 , further comprising:

means for adjusting a stochastic expected start time parameter for said at least one selected task and a stochastic expected end time parameter for said at least one selected task based at least in part on the calculated stochastic waiting time.

26. An apparatus according to claim 25 , further comprising:

means for setting a stochastic expected earliest start time parameter of at least one successor task of said at least one selected task in accordance with said adjusted stochastic expected end time parameter for said at least one selected task.

27. An apparatus according to claim 24 , wherein the stochastic waiting time for said at least one selected task is calculated based at least in part on:

(a) the determined stochastic parameters for said at least one selected task; and

(b) the determined stochastic parameters for each other one of said tasks that potentially conflicts with said at least one selected task.

28. An apparatus for analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the apparatus comprising:

means for determining stochastic parameters for each task of said plurality of tasks;

means for calculating a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said tasks; and

means for providing the calculated stochastic waiting time as an input to a production planning system;

wherein each of the stochastic parameters is expressed as a probability density function supported in a range between a first end point that represents a minimum value of the parameter and a second end point that represents a maximum value of the parameter, said probability density function exhibiting a peak value that represents a most likely value of the parameter.

29. An article of manufacture comprising:

a computer usable medium having computer readable program code means embodied therein for analyzing a manufacturing system, the system including a plurality of manufacturing resources, a set of orders being currently appointed for processing by the manufacturing system, each order of the set of orders requiring performance of at least one task, each task to be performed by at least a respective one of the manufacturing resources, the computer readable program code means in said article of manufacture comprising:

computer readable program code means for determining stochastic parameters for each task of said plurality of tasks;

computer readable program code means for calculating a stochastic waiting time for at least one selected task of said plurality of tasks, said calculating based at least in part on said stochastic parameters of said task; and

computer readable program code means for providing the calculated stochastic waiting time as an input to a production planning system;

wherein the calculated stochastic waiting time for said at least one selected task is expressed as a probability density function supported in a range between a first end point that represents a minimum waiting time and a second end point that represents a maximum waiting time, said probability density function exhibiting a peak value that represents a most likely waiting time.