Systems, methods and apparatus for management of a closed loop production system for use in the production of a formulation-based product
An order relating to a formulation-based product is received, wherein fulfilling the order requires production of the formulation-based product at a first location, transport of the formulation-based product in a vehicle to a second location different from the first location, and performance of an activity with respect to the formulation-based product at the second location. First information relating to a first change made to the formulation-based product at the first location is received, from the first location, prior to transport of the formulation-based product. Second information relating to a second change made to the formulation-based product during transport of the formulation-based product is received during transport of the formulation-based product. Third information relating to the activity performed with respect to the formulation-based product at the second location is received from the second location.
1. A method of producing a formulation-based product, the method comprising:
storing, in a memory, a formulation of a concrete mixture, the formulation specifying a plurality of components and respective quantities;
identifying, by a processor, a plurality of production facilities capable of producing the concrete mixture, each production facility associated with a respective locality, each production facility being located remote from the processor; and
performing, by the processor, the following actions, for each respective one of the plurality of production facilities:
identifying a factor that is associated with the corresponding locality and relates to a particular one of the plurality of components;
modifying the formulation, based on the factor, to generate a localized version of the formulation for use at the respective production facility, wherein the localized version of the formulation includes a local component different from the plurality of components specified in the formulation;
storing the localized version associated with the respective production facility in the memory, the memory being located remote from the respective production facility;
receiving an order for the concrete mixture, the order specifying the concrete mixture and the plurality of components;
selecting a production facility from among the plurality of production facilities;
causing a localized concrete mixture including the local component to be produced at the selected production facility based on the localized version of the formulation;
determining a first cost of the concrete mixture specified in the order and a second cost of the localized concrete mixture produced using the local component;
determining an impact of use of the local component on the customer's profitability; and
providing to the customer, via a network, access to a web page showing, simultaneously, information indicating the localized component, a difference between the first cost of the concrete mixture specified in the order and the second cost of the localized concrete mixture produced using the local component, and the impact of use of the local component on the customer's profitability.
2. The method of claim 1 , further comprising:
storing the localized version of the formulation in association with the formulation.
3. The method of claim 1 , wherein modifying the formulation further comprises modifying a quantity associated with the particular one of the plurality of components.
4. The method of claim 1 , wherein modifying the formulation further comprises adding a second component to the formulation.
5. The method of claim 1 , further comprising:
selecting a second plurality of production facilities from among the plurality of production facilities; and
for each of the second plurality of production facilities:
transmitting, to a system associated with the respective production facility, a respective localized version of the formulation associated with the respective production facility.
6. The method of claim 1 , wherein the factor comprises one of a local cost factor, a local product availability factor, and a local market preference factor.
7. A production management system comprising:
a plurality of production facilities, each production facility being adapted to produce one or more concrete mixtures;
a memory adapted to store a plurality of formulations, each formulation specifying a respective concrete mixture, a plurality of components associated with the respective concrete mixture, and, for each component, a quantity corresponding to the respective component;
a first processor adapted to:
receive an order specifying one of the plurality of formulations, the specified formulation specifying at least a particular component and a particular quantity associated with the particular component;
a second processor adapted to:
identify a local factor associated with a selected production facility, wherein the local factor affects one of an availability and a cost of the particular component; and
determine a modified formulation of the concrete mixture, based on the local factor, wherein the modified formulation specifying a second non-zero quantity of the particular component, the second non-zero quantity being different from the particular quantity specified in the specified formulation;
store the modified formulation in the memory; and
cause the concrete mixture to be produced at the selected production facility, based on the modified formulation.
8. The production management system of claim 7 , wherein the second processor is further adapted to:
determine a theoretical cost of a theoretical concrete mixture produced according to the specified formulation and an actual cost of the concrete mixture produced based on the modified formulation; and
store, in the memory, the order, first information indicating the change from the particular quantity to the second non-zero quantity and second information indicating a difference between the theoretical cost and the actual cost.
9. The production management system of claim 8 , wherein the second processor is further adapted to:
cause a processing device to display the difference between the theoretical cost and the actual cost.
10. The production management system of claim 8 , wherein the second processor is further adapted to:
cause a processing device to display an impact on profitability caused by use of the modified formulation.
11. The production management system of claim 7 , wherein the second processor is further adapted to:
determine that a local version of the modified formulation stored in a second memory located at the selected production facility is different from the modified formulation; and
update the local version of the modified formulation based on the modified formulation.
12. The production management system of claim 7 , wherein the second non-zero quantity is less than the particular quantity.
13. The production management system of claim 7 , wherein the particular component is one of water, cementitious, fly ash, fine aggregate, and course aggregate.
14. The production management system of claim 7 , further comprising:
a second memory adapted to store information indicating, for each of the plurality of production facilities, a respective local factor that affects one of an availability and a cost of one or more components associated with the specified formulation.
15. A system of interconnected elements used in a production management system, the system comprising:
a plurality of concrete production facilities, each concrete production facility being adapted to produce one or more concrete mixtures, each concrete production facility comprising a processing device adapted to control production of concrete mixtures at the respective concrete production facility;
a network adapted to carry communications;
a processing device linked to each of processing devices located at the plurality of production facilities via the network, the processing device comprising:
a memory adapted to store a plurality of formulations, each formulation specifying a respective concrete mixture, a plurality of components associated with the respective concrete mixture, and, for each component, a quantity corresponding to the respective component;
a processor adapted to:
receive an order specifying one of the plurality of formulations, the specified formulation specifying a concrete mixture having at least a particular component and a particular quantity associated with the particular component;
identify a local factor associated with a selected one of the concrete production facilities, wherein the local factor affects one of an availability and a cost of the particular component; and
determine a modified formulation of the specified concrete mixture, based on the local factor, wherein the modified formulation specifying a second non-zero quantity of the particular component, the second non-zero quantity being different from the particular quantity specified in the specified formulation;
store the modified formulation in the memory; and
instruct the processing device of the selected concrete production facility to produce the specified concrete mixture, based on the modified formulation.
16. The system of claim 15 , wherein the second processor is further adapted to:
determine a theoretical cost of a theoretical concrete mixture produced according to the specified formulation and an actual cost of the concrete mixture produced based on the modified formulation; and
store, in the memory, the order, first information indicating the change from the particular quantity to the second non-zero quantity and second information indicating a difference between the theoretical cost and the actual cost.
17. The system of claim 16 , wherein the processor is further adapted to:
cause a second processing device to display the difference between the theoretical cost and the actual cost.
18. The system of claim 16 , wherein the processor is further adapted to:
cause a second processing device to display an impact on profitability caused by use of the modified formulation.
19. The system of claim 15 , wherein the second processor is further adapted to:
determine that a local version of the modified formulation stored in a second memory located at the selected production facility is different from the modified formulation; and
update the local version of the modified formulation based on the modified formulation.
20. The system of claim 15 , wherein the second non-zero quantity is less than the particular quantity.
21. The system of claim 15 , wherein the particular component is one of water, cementitious, fly ash, fine aggregate, and course aggregate.