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KAYROS

Dynamic production planning

...is a product for dynamic production planning. It plans any order pool on the most complex production networks with the aim of minimizing setup costs and meeting deadlines. The underlying CORTEX technology enables KAYROS to achieve the highest calculation quality with the shortest calculation times.

In many industrial productions, the decisions when to produce which order, on which machine and how, are still largely made manually. Since more and more flexibility and shorter reaction times are expected from many productions, this method of planning increasingly reaches its limits. The results are missed deadlines, unnecessarily high setup costs and ultimately unused optimization potential. KAYROS offers a solution for that.

KAYROS can take over the planning for almost any production process. Its major strengths are:

  • optimized production planning that leads to lower setup costs and lower raw material consumption.
  • adherence to schedules and early detection of capacity bottlenecks
  • short computing times that enable dynamic production planning and adaptation
  • taking into account of transport
  • flexible machine models that can meet even the most specific machine requirements
  • management of limited resources needed at different times in different parts of the production network (tools)

Modeling of machines

Within KAYROS, each machine can be modeled in such a way that all parameters relevant to production planning can be taken into account. The approach is as follows:

  1. A machine can be put into different states by changeover processes. This can also mean switching certain modules on or off or removing them. A changeover process costs time, money and possibly raw material resources.
  2. The machine can execute certain processes in any state. Each process costs time and money. The latter can be linked to a quantity per hour, an area per time or any other measurable quantity.
  3. Every process that the machine carries out fulfills certain requirements that a product has.

Transport routes between certain machines or machine parts can also be defined and taken into account.

Modeling of products

In KAYROS, each product is defined as the sum of individual production steps. In each production step, a process puts the product or a part of the product into a new state closer to the end product. Each product or product component has specific requirements, which must be met in the course of production, often also in a specific sequence.

Synchronization

Modeling a machine creates a digital image of the real machine within KAYROS, which has the same capabilities as the original and generates the same costs. Now KAYROS needs to know when the machines are available. Equally important is the continuous feedback of each machine to KAYROS regarding its current condition. This enables KAYROS to react accordingly if, for example, a machine breaks down and the production needs to switch to other, possibly more expensive capacities. The more up-to-date the information, the better the result.

Another input for KAYROS are the orders. As soon as a new order is received, it must be sent to KAYROS. KAYROS will then schedule this order according to its priority and adjust the production schedule accordingly.

The KAYROS principle

KAYROS models the flow of orders through the production network and always calculates the best current production plan. Through the underlying modeling, KAYROS knows which products can be produced on which machines and thus always selects the production variant that comes closest to the objectives of "meeting deadlines" and "minimizing production costs". Due to its dynamic nature, it spontaneously adapts to unforeseeable influences such as machine failures and compensates these by rescheduling.


In the next step we want to work on a connection between PYTHIA and KAYROS, so that probability-based predictions will also influence production planning.

KAYROS Print

KAYROS Print is a variant of Kayros that has been developed specifcally for use in the graphics industry. It supplements the generic KAYROS solution with the following points:

  • Assembler: A module for splitting complex print orders such as brochures or books into folded sheets. The Assembler can take into account a wide variety of requirements, as well as different binding types.
  • sPrint One - KAYROS Connector: This connector ensures that the result of sPrint One can be processed by KAYROS Print. KAYROS then plans the print jobs for the entire postpress processes, such as cutting, folding, saddle stitching, punching, collating and many more.
  • KAYROS - sPrint One Connector: This connector provides the assembler with input data that influences its disassembly of multi-part products. If, for example, there is a bottleneck in saddle stitching, it will instruct the assembler to do more 4-pages decompositions in order to switch to the brochure line. Certain print dates will also be adjusted in such a way as to meet shipping deadlines.
  • Seamless integration of the KAYROS web service into the sPrint One user interface

With KAYROS Print and sPrint One, a print shop can be completely controlled cross site.


KAYROS and KAYROS Print are expected to be available as beta web services by early 2019.

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