Smart Daily Target Calculation Based on Process Dependencies

Smart Daily Target Calculation Based on Process Dependencies

We’re excited to roll out a new AI-powered target calculation system that dynamically sets daily production targets for each process, ensuring smooth flow, better resource alignment, and zero overproduction.

πŸ”’ Feature Activation Requirements

This feature will only be active if the following conditions are met:

  1. The factory has enabled the AI target method. 

  2. The section target for today’s orders has been defined. 

πŸ” How It Works:

The system now calculates daily targets per process by analyzing:

  • Section daily target (e.g., 1000 pieces)

  • Work-in-Progress (WIP) at each process

  • Finished pieces today

  • Process dependencies and parallel paths

  • Buffer time to ensure next-day readiness

Example Calculation:

πŸ” How the Target Flows Through the Line

🧱 Section Daily Target: 1000 Pieces

⏱ Buffer Time: 15 Minutes

The new system begins target calculations from the last processes in the production chain (like Process 5) and works its way upstream. This is intentional, because:

  1. Final processes define real output:
    Only what's finished at the end of the line counts toward delivery goals. So we ensure these processes get the full section target (e.g., 1000 pieces), adjusted by what they've already completed.

  2. Upstream processes must feed the last ones:
    Downstream demand pulls the work β€” so upstream processes like 3, 2, and 1 are assigned targets based on how much their child processes need. That way, no process overproduces or starves another.

🎯 Why Does the System Start from Process 5?

Instead of choosing a fixed process to start the calculations, the system now identifies the end-of-line process with the least remaining pieces and uses it to anchor the daily target distribution.

In this case: (Total Finished - Today's production)

  • Process 5 remaining = 3250 - 80 = 3170

  • Process 4 remaining = 4200 - 50 = 4150

  • Process 2 remaining = 5000 - 10 = 4990

βœ… Process 5 (least remaining β†’ critical anchor):

  • Target = 1000

  • This process must hit 1000 to meet section-level goals.

➑️ Process 4 (also downstream):

  • Remaining = 4200 - 50 = 4150

  • Gap vs Process 5 = 4150 - 3170 = 980 already produced more. 

  • Needs only 20 more to catch up

  • Target = 1000 - 980 = 20

➑️ Process 2 (alternative branch):

  • Remaining = 5000 - 10 = 4990

  • Gap vs Process 5 = 4990 - 3170 = 2820

  • Already far ahead

  • Target = 0 - 10 finished today = negative number so target is zero
    βœ… So Process 2 Target = 0 pieces

πŸ”„ Process 3 (feeds both 4 and 5):

  • Based on child needs:

    • From Process 5 β†’ 1000 - 30 WIP + 15/0.3 = 1020

    • From Process 4 β†’ 20 - 40 WIP + 15/0.5 = 10

βœ… Choose the maximum β†’ Target = 1020

⬆️ Process 1 (feeds both Process 2 and 3):

  • Child needs:

    • From Process 2 β†’ 0 - 10 + 15/1 = 5

    • From Process 3 β†’ 1020 - 200 WIP + 15/0.5 = 850

βœ… Choose the maximum β†’ Process 1 Target = 850

βœ… Summary of Daily Targets

ProcessTarget
1850
20
31020
420
51000

πŸš€ Benefits of This System

  • Ensures the right processes produce just enough to meet demand

  • Prevents overproduction and bottlenecks

  • Builds in buffer time to support next-day continuity

  • Dynamically adapts based on real WIP, finished counts, and process time


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