Abstract: A system for automatically replacing loaner parts within a loaner system to prevent loaner system callback. In response to selecting a loaner system within loaner inventory data, it is determined whether the selected loaner system is required to be returned based on a target return date for the selected loaner system. In response to determining that the selected loaner system is not required to be returned, a notification is automatically generated and sent to a customer to return expiring loaner parts within the selected loaner system based on loaner part rules. A part replacement order is automatically generated for replacement loaner parts for each of the expiring loaner parts. Then, the replacement loaner parts are automatically shipped to the customer to replace the expiring loaner parts to prevent callback of the selected loaner system.

Abstract: A computer implemented method, apparatus, and computer program product for grouping orders. One or more original orders are received. The one or more original orders are grouped using grouping rules to form a set of grouped orders. Upon determining that the set of grouped orders cannot be completely filled, at least one short order is created. The at least one short order is grouped with the set of grouped orders using grouping rules to form a set of consolidated orders.

Abstract: A method for dynamically altering manufacturing routings to add, remove, or skip operations and combinations of operations within a shop floor control system in real-time to respond to current conditions. One aspect of the present invention is a computer-implemented method for dynamically generating a manufacturing production work flow. One embodiment of this method comprises receiving indication that an assembly has completed a manufacturing operation, the assembly having a work flow and a sampling strategy associated therewith; querying a data source for characteristics of a plurality of previously sampled components; querying a manufacturing floor control system for current production status; and dynamically updating the work flow for the assembly based at least in part on the sampling strategy, characteristics of the plurality of previously sampled components, and the current production status.

Abstract: A hybrid data collection and component installation scheme for optimizing equipment cost, throughput, and quality practices in a multi-stage manufacturing environment. A kit comprising a plurality of parts corresponding to an order for a product is received from one of the stages in the multi-stage manufacturing environment. The parts in the kit were validated in the stage using data collected about the plurality of parts in the stage. At a subsequent stage in the manufacturing environment, a determination is made if the product qualifies for mass installation. If the product qualifies for mass installation, a set of parts in the kit is selected for mass installation. The set of parts are re-verified using the data collected in the previous stage in the environment to determine if the set of parts selected for mass installation is valid. If valid, the set of parts are installed en masse.

Abstract: A manufacturing process for automatically delivering an appropriate level of instructions to a manufacturing operator on demand based on the manufacturing operator's level of activity and performance, the particular characteristics of the product being manufactured, and the particular production environment. Responsive to receiving an order for a product, the manufacturing process identifies an authorization level assigned to an operator performing a particular manufacturing activity on a part in the product and assigns a default level of instructions to the operator based on the authorization level. The process collects and models characteristics about the manufacturing environment, performance history of the operator, and knowledge decay of the operator to determine an appropriate level of instructions to provide to the operator performing a particular manufacturing activity. The manufacturing instructions associated with the appropriate level of instructions are then provided to the operator.

Abstract: Operator authorizations are autonomically adjusted in many ways to automatically account for many different variables. Operator authorization may be adjusted according to an operator's past activity record so previous experience is not lost when the operator is rehired. Operator authorization may be adjusted according to the operator's quality and performance. Operator authorization may also be adjusted by recognizing similar operations to those the operator is authorized to perform, and authorizing the operator to perform one or more similar operations. Operator authorization may also be adjusted to a lesser level or may be revoked for an operation based on the passage of time. A manufacturing system may efficiently track operators taking into account different activity periods, the passage of time, the operator's performance, and similar operations to autonomically adjust the authorization of the operators as needed.

Abstract: A manufacturing process for automatically delivering an appropriate level of instructions to a manufacturing operator on demand based on the manufacturing operator's level of activity and performance, the particular characteristics of the product being manufactured, and the particular production environment. Responsive to receiving an order for a product, the manufacturing process identifies an authorization level assigned to an operator performing a particular manufacturing activity on a part in the product and assigns a default level of instructions to the operator based on the authorization level. The process collects and models characteristics about the manufacturing environment, performance history of the operator, and knowledge decay of the operator to determine an appropriate level of instructions to provide to the operator performing a particular manufacturing activity. The manufacturing instructions associated with the appropriate level of instructions are then provided to the operator.

Abstract: A computer implemented method, computer program product, and data processing system for managing proxy parts that are exchangeable based on an active exchangeable proxy part list, a production history, and a true demand. A production history is used to compile a list of active exchangeable proxy parts. The most available active exchangeable proxy part is chosen as a proxy part in a unit. The target part in the unit's production order is overridden with the newly assigned proxy part number. Following the implementation of the proxy part, the proxy part is recovered. The proxy part is returned to production inventory, where it may be reassigned as a proxy part or implemented as a production part.

Abstract: A computer implemented method, a tangible computer usable medium, and a data processing system allocate materials to an automated purchase assembly conversion process to support a dynamic configure-to-order production operation. A configure-to-order backlog order is analyzed to determine demand for a particular purchase assembly. If the demand for the particular purchase assembly can be filled with an on-hand purchase assembly in inventory, the on-hand purchase assembly in inventory is allocated to fill the demand. If the demand for the particular purchase assembly can not be filled with an on-hand purchase assembly in inventory, a determination is made as to whether the demand for the particular purchase assembly can be filled by reallocating other similar on-hand purchase assembly in inventory and on-hand individual parts.

Abstract: A computer implemented method, apparatus, and computer program product for managing variable regulatory compliance in a supply chain. The process identifies a variable regulatory compliance for a production order. Variable regulatory compliance is a percentage of a given attribute of the production order in compliance with order compliance rules. The process selects a set of compliant parts based on a compliant supply-to-demand ratio. The set of compliant parts is a minimum number of compliant parts required to satisfy variable regulatory compliance. The process selects a set of non-compliant parts based on a non-compliant supply-to-demand ratio. The process generates a list of recommended parts for use in manufacturing a product specified by the production order. The list of recommended parts comprises the set of compliant parts and the set of non-compliant parts.

Abstract: A hybrid data collection and component installation scheme for optimizing equipment cost, throughput, and quality practices in a multi-stage manufacturing environment. A kit comprising a plurality of parts corresponding to an order for a product is received from one of the stages in the multi-stage manufacturing environment. The parts in the kit were validated in the stage using data collected about the plurality of parts in the stage. At a subsequent stage in the manufacturing environment, a determination is made if the product qualifies for mass installation. If the product qualifies for mass installation, a set of parts in the kit is selected for mass installation. The set of parts are re-verified using the data collected in the previous stage in the environment to determine if the set of parts selected for mass installation is valid. If valid, the set of parts are installed en masse.

Abstract: A computer implemented method, an apparatus, and computer usable program product for identifying a defective product is provided. A data processing system identifies a product status for products comprising at least one range of serial numbers. The data processing system then narrows the at least one range of serial numbers using a range flattening algorithm. The data processing system then applies a conditional mask algorithm to the at least one range of serial numbers to narrow the at least one range of serial numbers.

Abstract: A method is provided for use in connection with build ahead configurations (BAC's), for enabling a manufacturer to quickly identify the available BAC that is most suitable for use in completing a product order. In one embodiment, directed to a method for increasing efficiency in constructing individual products of a particular product type, each individual product has an associated specification set. A number of BAC's are initially constructed, wherein each BAC comprises an at least partially complete product of the particular type, and likewise has an associated specification set. An order is received for an individual product of the particular type, wherein the order defines each specification in the specification set for the ordered product.

Abstract: A method for associating objects in a manufacturing process. In response to an occurrence of an event for an object, a time is recorded of the event for the object. Entries for parts and assemblies associated with the object are located within a database. An entry of the event for the object is created within the database. The entry includes the event for the object, the time of the event for the object, and the entries for the parts and the assemblies associated with the object.

Abstract: A system for automatically replacing loaner parts within a loaner system to prevent loaner system callback. In response to selecting a loaner system within loaner inventory data, it is determined whether the selected loaner system is required to be returned based on a target return date for the selected loaner system. In response to determining that the selected loaner system is not required to be returned, a notification is automatically generated and sent to a customer to return expiring loaner parts within the selected loaner system based on loaner part rules. A part replacement order is automatically generated for replacement loaner parts for each of the expiring loaner parts. Then, the replacement loaner parts are automatically shipped to the customer to replace the expiring loaner parts to prevent callback of the selected loaner system.

Abstract: An improved manufacturing system for controlling the interchangeability of sets of parts during product installation. In response to receiving a request for an order, a parts list is created for the order. The illustrative embodiments determine whether each part in the parts list is present in current inventory stock. If any of a first group of parts in the parts list is not present in current inventory stock, the illustrative embodiments allow for determining that a second group of parts in the current inventory stock is a valid substitution group for replacing the first group of parts, wherein the number of parts in the first group of parts is not equal to the number of parts in the second group of parts. The illustrative embodiments then update the order by replacing the first group of parts in the parts list with the identified second group of parts.

Abstract: Real-time assembly and part validation (or “containment”) and auto-disposition in a manufacturing environment. Validation and auto-disposition are performed in a real-time, proactive manner where the validation and auto-disposition processing are not coupled to the installation process. Validation problems or issues may therefore be identified and resolved before an assembly or part is needed for installation.

Abstract: Embodiments of the present routing returned inventory assets and provide a method, system and computer program product for routing items in a manufacturing environment. In an embodiment of the invention, a method for routing items in a manufacturing environment can be provided. The method can include defining attributes of work pools in the manufacturing environment, defining a set of reuse strategies for use in the manufacturing environment, receiving a returned inventory asset in the manufacturing environment and obtaining at least one attribute of the returned inventory asset, comparing the obtained at least one attribute of the returned inventory asset to the set of reuse strategies to select the reuse strategy to apply to the returned inventory asset and applying the selected reuse strategy to the returned inventory asset to assign the returned inventory asset to one of the work pools in the manufacturing environment.

Abstract: Embodiments of the present invention address deficiencies of the art in respect to manufacturing production and provide a novel and non-obvious method, system and computer program product for reuse of cancelled products that are partially manufactured. In one embodiment of the invention, a method for reusing a partially manufactured product during a manufacturing process can be provided. The method can include reading a configuration of the partially manufactured product and reading a set of rules that match a given configuration with one of a set of defined target configurations. The method can further include executing the set of rules upon the configuration of the partially manufactured product so as to match the configuration of the partially manufactured product with a target configuration.

Abstract: Embodiments of the present invention provide a method, system and computer program product for controlling cancelled orders in a manufacturing environment. In an embodiment of the invention, a method for controlling cancelled orders in a manufacturing environment can be provided.