Browse Prior Art Database

%BMP%Search **Real-Time Disassembly Work Direction Based on Weighted Measurements

IP.com Disclosure Number: IPCOM000181347D
Original Publication Date: 2009-Mar-30
Included in the Prior Art Database: 2009-Mar-30
Document File: 6 page(s) / 148K

Publishing Venue

IBM

Abstract

Disclosed are the algorithms and data structures that transform an ever changing set of returned assets and a conflicting set of priorities into an optimized disassembly and inventory recovery work direction. This is particularly useful for complex configure-to-order product.

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%BMP%Search **Real-Time Disassembly Work Direction Based on Weighted Measurements

Problem:


In a high volume manufacturing environment there are often orders that cancel or return to the plant. These returned or unused assets take up significant space and carry a significant inventory value. Industry standard material and production control applications facilitate returning the inventory to stock for reuse, however in a sub-optimal fashion, particularly for configure-to-order product. (Note that the invention refers interchangeably to "disassembly" and "tear down" throughout this publication.)

Typically, returned product moves from a warehouse to a disassembly area for processing. The decision to move a product or asset for disassembly is ad hoc, or at best based on a limited number of factors. Consideration of all factors involved has not been previously feasible due to the number of factors involved and their collective complexity. Some key factors include space availability, worker availability, inventory coverage for outbound orders, inventory usability, and planned Material Requirements Planning (MRP) part pulls from warehouses.

One example of sub-optimization involves missed outbound shipments due to inventory shortages, but with a lack of knowledge that some of the short inventory existed in the returned assets. A somewhat less extreme example would be unnecessary inventory pulls and payment for inventory that also exists in the returned assets. On the contrary are situations where the inventory in returned assets was believed useable, but actually was not, such that the effort to remove and return the inventory to stock is wasted.

Solution:


Description of Invention:
This invention provides a dynamic method to automate the identification and prioritization of returned part inventory based on changing Manufacturing demands. The design includes both the materials handling as well as materials usage in the manufacturing process.

Advantages:

Reduce inventory levels and carrying costs, as inventory with immediate demand

1.

is returned to stock and reused


Reduces handling time and manual workload to identify inventory needed, which

2.

can also be directly related to improved cycle times.

Improve warranty and scrap costs as inventory is returned timely

3.

Reduced customer impact for miss-ships resulting from inventory from demand

4.

inventory tied up in cancelled and returned orders.

Provide a controlled mechanism to allow the continued shift to a lower cost, lower

5.

skilled work force for direct manufacturing activities and eliminate need for manual effort.

1

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Key Design Elements:

End to end process workflow for the optimization of returned asset priorities

1.

(refer to Fig. 1).

Return order measurements determination algorithm (refer to Fig. 2).

2.

Priority determination algorithm (refer to Fig. 3).

...