US007406358B2

(12) Ulllted States Patent (10) Patent N0.: US 7,406,358 B2

Preiss (45) Date of Patent: Jul. 29, 2008

(54) KANBAN CONTROL CYCLE SYSTEM OTHER PUBLICATIONS

75 . - - Qiu et al., Distributed WIP control in Advanced semiconductor
( ) Inventor‘ Martm Prelss’ Karlsruhe (DE) manufacturing, 2002, IEEE ASMconfrernce, p. 49-45.*
~ . - Pattita Suwanruji, A Simulation Test Bed For Production and Supply
(73) Asslgnee' SAP Aktlengesellschaft’ Wa11dOrf(DE) Chain Modeling, Dept. of Mechanical Manufacturing Engineering,
>l<
. -
. . . . 2003 a p. 1174-1182.*

( ) Nonce' SubJeCt.tO any (jllsglalmeé’. the germdof?glg Desrochers A. A. et al., “Complex Token Petri Nets”, 2003 IEEE
gage? 11552331 e0 3; a Juste un er International Conference on Systems, Man and Cybernetics, vol. 5 of
~ ~ - y ys~ 5, Oct. 5, 2003, pp. 1153-1160.
Matta A et al., “Analysis of assembly systems controlled With
(21) Appl- N05 11/171,865 kanbans”, European Journal of Operational Research, Amsterdam,
_ NL, vol. 166, No. 2, May 11, 2004, pp. 310-336.
(22) Flled: Jun- 301 2005 Proth J -M, “Petri nets for modeling and evaluating deterministic and
stochastic manufacturing systems”, Proceedings of the Seventh Inter
(65) Pl‘iOl‘ PllbliC?tiOIl Data national Workshop on Saint Malo, France Jun. 3-6, 1997, Los
Us 2007/0005411A1 Jan‘ 4, 2007 Alamitos, CA, USA, IEEE, Jun 3, 1997, pp 2 1
' . . - 4.

* cited by examiner
51 Int. Cl.
( ) G06F 19/00 (2006.01)
Primary ExamineriKidest
_
Bahta_ _
(52) us. Cl. ............................ .. 700/99; 700/107; 705/8 (74) Align/6% 1486"’! Or FlrmiFlsh & Rlchardson RC
(58) Field of Classi?cation Search ......... .. (57) ABSTRACT

See application ?le for complete search history.

_ Modeling a process chain includes mapping processes in the
(56) References Clted process chain to control cycles, de?ning states for the control
U_S_ PATENT DOCUMENTS cycles, and de?ning couplings between states in different
control cycles such that a state change 1n one control cycle
20056105114255 21* 1;; gufmg et 2111' ~~~~~~~~~~~~~~~~~ " 705/8
riep et a .
causes a state change in another control cycle. The control
2003/0078831 A1 * 4/2003 Kuettneret a1. ............. .. 705/10 Cycles may be Kanban Control Cycles‘
2005/0261954 A1* 11/2005 705/10
2006/0015416 A1 * l/2006 Hoffman et al. ............ .. 705/28 21 Claims, 7 Drawing Sheets

Analyze proces chain for items 702

1
Map process chain of each item 704
into Kanban control cycle

1
De?ne state sequence 706

l
De?ne leading control cycle 708

1
Define dependent control cycle 710

1
De?ne state sequence coupling 712

Control process by triggering 714

state changes
US. Patent Jul. 29, 2008 Sheet 1 of7 US 7,406,358 B2

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US. Patent Jul. 29, 2008 Sheet 2 of7 US 7,406,358 B2
US. Patent Jul. 29, 2008 Sheet 3 of7 US 7,406,358 B2

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US. Patent Jul. 29, 2008 Sheet 4 of7 US 7,406,358 B2

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US. Patent Jul. 29, 2008 Sheet 6 of7 US 7,406,358 B2
US. Patent Jul. 29, 2008 Sheet 7 of7 US 7,406,358 B2

Analyze proces chain for items 702

Map process chain of each item 704

into Kanban control cycle /
l
De?ne state sequence 706
/
V

De?ne leading control cycle 703

/
‘

Define dependent control cycle /710

V

-
De?ne state sequence coupllng /712

Control process by triggering 714

state changes /
FIG. 8
 US 7,406,358 B2
1 2
KANBAN CONTROL CYCLE SYSTEM control cycles such that a state change in one control cycle
causes a state change in another control cycle.
TECHNICAL FIELD The foregoing aspect may include designating one of the
control cycles to be a leading control cycle, designating one of
This patent application relates generally to Kanban control the control cycles to be a dependent control cycle, and de?n
cycles and, more particularly, a system that uses Kanban ing a coupling betWeen the leading control cycle and the
control cycles to replenish items. dependent control cycle such that a state change in the depen
dent control cycles is caused by a state change in the leading
BACKGROUND control cycle. The control cycles may be de?ned in a softWare
system for supporting material How in the process chain. The
“Kanban” is a Japanese term that means signal. Kanban is control cycles may be Kanban control cycles. The couplings
one of the primary tools of a just-in-time manufacturing sys betWeen states may be de?ned using a matrix that indicates an
tem (meaning a planning system for manufacturing processes effect of a state in one control cycle on a state in another
that optimiZes availability of material inventories at a manu control cycle.
facturing site to only What, When and hoW much is necessary). A consistency rule may be de?ned. The consistency rule
Kanban signals a replenishment process for production and may ensure correct relationships betWeen states in at least one
materials, and maintains a generally orderly and e?icient How of the dependent control cycle and the independent control
of materials throughout a manufacturing process. Kanban cycle. An error state may be de?ned in at least one of the
may be implemented via a printed card that contains speci?c control cycles. An error state of a ?rst control cycle may be
information such as item name, description, quantity, etc. 20 linked With an error state of a second control cycle. At least
Kanban control cycles de?ne a replenishment process in one of the states may be de?ned in at least one Kanban card.
terms of operational states. A Kanban control cycle can be The state sequence may be de?ned by at least one set of states
characterized as a sequence of different operational states. of different control cycles having at least one state coupling
Kanban control cycles occur betWeen a supplier and a con type
sumer, i.e., the one replenishing an item and the one request 25 The details of one or more examples are set forth in the
ing that the item be replenished, respectively. The item can be accompanying draWings and the description beloW. Further
any kind of material, such as a component or an assembly, that features, aspects, and advantages of the invention Will
needs to be replenished. In a Kanban control cycle, a signal become apparent from the description, the draWings, and the
indicating that the material needs to be replenished is sent claims.
from the customer to the supplier. This signal, called the 30
Kanban, may be part of an electronic message or an actual DESCRIPTION OF THE DRAWINGS
physical device, such as a card. The operational state of the
Kanban may be modi?ed to provide item-related information, FIG. 1 shoWs a supply chain monitored by a Kanban con
as described beloW. trol cycle.
By Way of example, a material may be needed by a con 35 FIG. 2 shoWs a state sequence chart for a leading control
sumer for use in a machine or process. As a result of this need, cycle and a dependent control cycle in the Kanban control
an operational state of the Kanban is set from “full” to cycle.
“empty”. The consumer therefore sends a Kanban to a sup FIG. 3 shoWs a state sequence matrix of the leading control
plier instructing the supplier to provide more of (e. g., a speci cycle.
?ed amount of) the material. In this example, the Kanban 40 FIG. 4 shoWs a state sequence matrix of the dependent
identi?es the material, the amount of the material, and the control cycle.
consumer. After the Kanban arrives at the supplier, the sup FIG. 5 shoWs a state sequence coupling betWeen the lead
plier processes the order and sends the material to the con ing control cycle and the dependent control cycle.
sumer. The state of the Kanban is then changed from “empty” FIG. 6 shoWs state sequence charts foruse in implementing
to “full”. 45 loose coupling.
States of a Kanban correspond to states of a cycle that is FIG. 7 shoWs a Kanban card.
performed to replenish an item. Electronic Kanban systems FIG. 8 shoWs a ?owchart of a method for monitoring a
associate a state change of a Kanban With related electroni supply chain using a Kanban control cycle.
cally-controlled actions, such as printing Kanban cards, visu Like reference numerals in different ?gures indicate like
aliZing replenishing scenarios, creating and sending replen 50 elements.
ishment orders (e.g. electronically transmitting a purchase
order to a supplier), and updating inventory levels. DETAILED DESCRIPTION
Existing Kanban control cycles operate on an item-by-item
basis, making it dif?cult to address more than one item at a Kanban control cycles provide a method to monitor, con
time. This can be problematic, particularly in situations, such 55 trol, support, and automate production and supply chain man
as supply chains, Where the supply of one item depends on the agement for items, based on the physical inventory of items
supply of another item. during manufacturing. Items that are necessary during pro
duction may be readily available in small quantities. Replen
SUMMARY ishment of such items can be initiated via a Kanban control
60 cycle by issuing a Kanban control card (referred to herein as
This patent application describes methods and apparatus, “the Kanban”). In this embodiment, the Kanban describe the
including computer program products, for using a Kanban items to be supplied, the quantity of the items, and the cus
control cycle to monitor a production system. tomer, meaning to Whom the items are to be delivered.
In general, in one aspect, the invention is directed to mod The application describes a system, in particular softWare,
eling a process chain, and includes mapping processes in the 65 for use in controlling replenishment processes for related
process chain to control cycles, de?ning states for the control items using Kanban control cycles. Brie?y, the softWare
cycles, and de?ning couplings betWeen states in different described herein maps a replenishment process of each item
 US 7,406,358 B2
3 4
into a corresponding control cycle, de?nes at least tWo opera Thus, using Kanban control cycles, manufacturing pro
tional states (or simply, “states”) for each cycle, de?nes a state cesses can be controlled and automated, thereby reducing
sequence for each control cycle, and de?nes a state sequence manual intervention in the process. As noted, a computer
coupling betWeen control cycles such that a change in state of system may be used to provide Kanban control cycles for
a replenishment process of one item triggers a corresponding 5 items that are coupled to each other. What is meant by cou
change of state of a replenishment process of a related item. pling here is that a state of a ?rst control cycle can cause, or
Such changes of state can include, but are not limited to, can be caused by, a state of a second control cycle. Coupling
printing Kanbans, updating monitoring displays, and creating of a plurality of control cycles extends automatic replenish
or updating procurement orders, inventory levels, etc. ment to plural items, as illustrated beloW.
A process called “rigid coupling” may be used to effect FIG. 2 shoWs state sequence charts for a leading control
state sequence coupling in Kanban control cycles. According cycle 200 and a dependent control cycle 202. Leading control
to this process, one control cycle is designated the “leading cycle 200 is de?ned by four different states: A, B, C and D.
control cycle”, and at least one other control cycle is desig State changes are de?ned by state transitions 204 to 216. For
nated the “dependent control cycle”. State sequences cou example, a state change fromA to B is de?ned by transition
pling are coupled in that any state Within one of the dependent 204. A state change from C to A is de?ned by transition 214.
control cycle is caused by at least one state in the leading Dependent control cycle 202 has three states: F, G and H.
control cycle. State changes are de?ned by state transitions 220 to 228. State
Another process, called “loose coupling”, may be used to changes in dependent control cycle 202 are triggered (in this
effect state sequence coupling in Kanban control cycles. example, exclusively) by a coupling 240 to 248.
According to this process, tWo Kanban control cycles, CC1 20 In this embodiment, the coupling betWeen leading control
and CC2, can be coupled loosely using a state sequence cycle 200 and dependent control cycle 202 is a rigid coupling
coupling, Which constitutes a collection of state sets. Each (as de?ned above). Dependent control cycle 202 is not able to
state set includes a state in a state sequence of CC1, a state in change its states F, G, H until a neW state in leading control
a state sequence of CC,2 and a “state coupling type”. The state cycle 200 is achieved. The supply chain containing the lead
coupling type controls Whether the coupling betWeen tWo 25 ing and dependent control cycles can include items that are
cycles is bidirectional (change of state in CC1 triggers a alWays used in combination. The state coupling can be stored
change of state in CC2, and vice versa) or one-directional, and a state coupling type.
Whether a change in state of one control cycle, e.g., CC2, must By Way of example, a garage may need to be supplied
be being triggered by another control cycle, e.g., CC1. regularly With spare motors and parts from a central storage
FIG. 1 illustrates a supply chain 100 for items 112. FIG. 1 30 facility. In this example, spare motors and parts can be trans
shoWs a consumer 104 that requires items 112, and a supplier ported in a single container, and constitute items of a Kaban
102 that provides item 112. Items 112 are 20 transported control cycle. Using a Kanban control cycle, replenishment of
betWeen supplier 102 and consumer 104 in containers 106. each item can be controlled separately. HoWever, While the
Items 112 are used in a production line 110. Several items Kanban control cycles are independent, each Kanban control
112a, 1121) can be kept in stock. Each item 1120 used in 35 cycle is triggered individually, i.e., a Kanban is generated for
production line 110 is scanned by a barcode scanner 108. By each item. This can be problematic because it requires manual
scanning items 112 When used, stock of items 112 is moni intervention, Which can be error prone.
tored electronically. Coupling control cycles 200 and 202 can reduce the
The supply chain of items 112 shoWn in FIG. 1 is controlled amount of manual interaction required to replenish the items.
by an event-controlled Kanban control cycle. In an event 40 For example, each time spare motors need to be replenished,
controlled Kanban control cycle, replenishment of items 112 corresponding replacement parts therefor can also be
can be correlated to item requirements. Thus, items 112 can ordered. A Kanban “impulse” can constitute scanning of an
be made available only When items 112 are needed, e. g., stock order code. This impulse can trigger leading control cycle 200
of an item is beloW a minimum level. to change its state from D “full” to B “empty”. The dependent
In this implementation, a current stock level is described by 45 control cycle thereby is triggered to also change its state from
control cycle states “full” and “empty”. A request for an item H “full” to F “empty”.
can be triggered by an event, such as scanning a last item 112 TWo Kanban cards, one for each item (motors and parts),
in stock. At this point, the control cycle state may be set to are generated by the consumer and provided to the supplier. In
“empty”. When the state is “empty”, a Kanban 116 (e.g., a this example, the supplier can produce the items and send
card) is generated and sent to the supplier 102. 50 them back to the consumer in one container. At the consum
The supplier 102 receives the Kanban and extracts replen er’s site, the container can be scanned, e.g., by a barcode
ishment information concerning item 112 from Kanban 116. scanner. Following scanning, or in response thereto, the state
The replenishment information can be obtained by scanning of the leading control cycle 200 can be set to D, “full”.
a barcode on the Kanban. The barcode is linked to master data Because the tWo cycles are coupled, the state of dependent
the customer’s database. The master data can contain, e.g., 55 control cycle 202 is also set to H “full”. Leading control cycle
information pertaining to (e.g., identifying) the item and 200 and dependent control cycle 202, and the coupling
replenishment requirements pertaining to the item. As noted, betWeen them, can be customiZed once in order to automate
items 112 are sent in containers 106 from supplier 102 to combined processing in any manner desired.
consumer 104. State changes of control cycles can be subject to certain
When the consumer 104 receives the requested items, the 60 restrictions. While customiZing the control cycles, the state
consumer can process the items automatically, e.g., scanning sequences can be de?ned. Exemplary states of control cycle
a barcode on the each container 106. Information from the 202 may be “Wait” (A), “empty” (B), “in process” (C), and
barcode can be used by a computer system (not shoWn) at the “full” (D). Additional states can be “in transit” or “in use”,
consumer to update the database, and thereby keep track of each describing a temporal state of an item. “Wait” can indi
items 112. The state of the control cycle for item 112 can then 65 cate that the material is used up, but that replenishment is not
be set to “full”. Kanban 116 can then be deactivated/deleted/ yet required. “In process” can indicate that the requested item
destroyed. is currently in production. “In transit” can indicate that an
 US 7,406,358 B2
5 6
item is on its Way from the supplier to the consumer. “In use” Control cycle 302 can also have different states “initial”, L,
can indicate that the item is currently being used by the and M. State transitions are permitted betWeen “initial” and L
consumer. 314, betWeen L, and M 316, betWeen M and L 318, and
An error state “error” 230, 232, Which indicates a process betWeen M and “initial” 320.
error, can be used in each control cycle 200, 202. For example, A state coupling matrix may facilitate customiZation of
“error” can indicate that a desired state could not be set couplings betWeen control cycles 300 and 302. It is also be
successfully in a control cycle. Because control cycles 200, possible to store, in the state coupling matrix, a state coupling
202 are coupled, an error state in one of control cycles 200, type indicating Whether a coupling is bidirectional or one
202 causes an error state in the other control cycle 200, 202. directional. The state coupling matrix may also store one or
Errors typically need to be resolved manually. more indications regarding to Whether a state change can
FIG. 3 illustrates a state sequence matrix de?ning state occur Without being triggered by a coupling control cycle, or
changes of leading control cycle 200. In FIG. 3, the columns Whether a state change must be triggered by another control
indicate states and the roWs indicate state transitions. “S” cycle in order to occur.
indicates the start state of a state change and “E” indicates the By Way of example, a one-directional state coupling
end state of the state change. For example, the state change betWeen state I and state L 340 is possible. This might be
from “A” to “B” is represented by state transition 204; the useful if a replenishment order for an item, Which is moni
change from “A” to “C” is represented by state transition 21 tored by control cycle 300, causes an item controlled by
0; and the change from “C” to “A” is represented by state control cycle 302 to be provided. Thus, if, in control cycle
transition 214. The matrix facilitates customization of state 300, a consumer order is received, control cycle 300 changes
changes betWeen states “A” to “D” in leading control cycle 20 from its “initial” state to its “empty” state I in state transition
200. 304. When control cycle 300 reaches state I, state L in control
FIG. 4 illustrates a state sequence matrix de?ning state cycle 302 is triggered. Corresponding replenishment orders
changes for dependent control cycle 202. As above, columns for the items can be generated and provided to suppliers.
indicate states and roWs indicate state transitions. “S” indi Which orders are generated depends on Which items are con
cates a start state of a state change and “E” indicates the end 25 trolled by control cycles 300, 302. Thereafter, the replenish
state of a state change. For example, the state change from “F” ment processes can run automatically Without manual inter
to “G” is represented by state transition 220; the state change vention.
from “F” to “H” is represented by state transition 224; and the It is possible to monitor the replenishment status of several
state change from “H” to “F” is represented by state transition items using Kanban control. For example, assume that an
228. The matrix facilitates customization of state changes 30 item controlled by control cycle 302 is necessary to produce
betWeen states “F” to “H” in dependent control cycle 202. an item controlled by control cycle 300. In this case, a state
FIG. 5 illustrates a state sequence coupling matrix. In the “full”, Which is represented by state M in control cycle 302,
matrix of FIG. 5, coupling betWeen states of leading control can cause (by Way of an unidirectional state coupling 342)
cycle 200 and dependent control cycle 202 is customiZed. control cycle 300 to change its state from I to I, Where state I
Each coupling 240 to 246 is assigned to a state “A” to “D” in 35 corresponds to “in process”. Control cycle 300 can proceed to
the leading control cycle and a state “F” to “H” in the depen state “K” once the item is provided.
dent control cycle. For example, coupling 240 is assigned to With loose coupling, it is possible to provide one-direc
state “A” and state “F”, thereby indicating a coupling betWeen tional or bidirectional state couplings betWeen control cycles
these states. The couplings customiZed in this matrix corre 300, 302. In this example, a one-directional state coupling
spond to the couplings in FIG. 2. 40 causes a state change in control cycle 300 to effect a state
A consistency check can be performed using the state change in control cycle 302, but not vice versa. A bidirec
sequence coupling matrix. From each coupling, the state of tional state coupling can cause a state change in either control
the leading control cycle is obtained. For coupling 244, this is cycle 300 to effect a state change in control cycle 302, or vice
state “C”. State “C” can be changed into state “D” via state versa.
transition 208 in FIG. 3 and into state “A” via state transition 45 With loose coupling, it is also possible to de?ne Whether
216 in FIG. 3. From the coupling matrix, it is also evident that state changes in one control cycle can be initiated indepen
state “D” is coupled to state “H” and state “A” is coupled to dently of state changes or states in another control cycle, or
state “F”. State “C” is coupled to state “G” through coupling Whether such state changes depend on state changes in
244. A state transition of state “C” can lead to states “A” or another control cycle. It is also possible to couple states of one
“D”. In the dependent control cycle, this can lead to state 50 control cycle 300 With other states of more than one other
changes from “G” to “F” or to “H”. These changes are pos control cycles. Loose coupling also makes it possible to
sible, as is evident from state transition 226 representing the couple a state of a ?rst control cycle With a state of a second
state change from “G” to “F” and state transition 222 repre control cycle, to couple the state of the second control With a
senting the change from “G” to “H” in FIG. 4. In this example, state of a third control cycle, and so on.
a state change from “D” to “C” Would not be alloWed. This is 55 As noted above, a Kanban can be a physical device, such as
because, in the dependent control cycle, a state change from a card, or an electronic element, such as a signal or message.
“H” (Which is coupled to “D” through coupling 246) to “G” FIG. 7 illustrates a Kanban card 116. Kanban card 116 can
(Which is coupled to “C” through coupling 244) is not avail include an item identi?er (ID) that identi?es a requested item,
able. a lot that de?nes a number of ordered items, a consumerID
FIG. 6 illustrates a state sequence chart for a loose coupling 60 that identi?es a consumer requesting the item, a supplierID
betWeen a control cycle 300 and a control cycle 302. This that identi?es a producer of the item, a state of the underlying
loose coupling betWeen control cycles 300 and 302 can also Kanban control cycle that de?nes a state of the control cycle,
be implemented in softWare executing on one or more com and a barcode. The barcode can be used to scan the Kanban
puters. Control cycle 300 can have different states I, J, K and card and to alloW electronic processing of data concerning the
“initial”. State transitions are permitted betWeen the states 65 item. The barcode also de?ne initiating events, Which trigger
“initial” and I 304, betWeen states I and J 306, between I and state changes automatically. That is, data represented by the
K 308, betWeen K and “initial” 312, and betWeen I and K 310. barcode can trigger state changes, as described herein.
 US 7,406,358 B2
7 8
FIG. 8 is ?owchart showing a process 800 that uses Kanban include all forms of non-volatile memory, including by way
control cycles in the manner described herein. In the ?ow of example, semiconductor memory devices, e.g., EPROM,
chart, processes of a chain are analyzed (802). A Kanban EEPROM, and ?ash memory devices; magnetic disks, e.g.,
control cycle is mapped (804) to each item in the process internal hard disks or removable disks; magneto-optical
chain. States of the resulting Kanban control cycles are cus disks; and CD-ROM and DVD-ROM disks.
tomiZed (806). During state de?nition, the process chain can The processes can be implemented in a computing system
further be mapped into the control cycle by customizing a that includes a back-end component, e.g., as a data server, or
sequence of states within each control cycle. The state that includes a middleware component, e.g., an application
sequence, as described with respect to FIGS. 3 and 4, corre server, or that includes a front-end component, e.g., a client
sponds to state changes allowed within a control cycle. After computer having a graphical user interface or a Web browser
customiZing the Kanban control cycles, one control cycle is through which a user can interact with an implementation of
designated (708) as leading control cycle 708. Other control the processes, or any combination of such back-end, middle
cycles can be designated (710) as dependent control cycle(s). ware, or front-end components. The components of the sys
A state sequence coupling is de?ned (712) to provide cou tem can be interconnected by any form or medium of digital
pling between the leading control cycle and the dependent data communication, e.g., a communication network.
control cycle. Such a coupling is, for example, illustrated in Examples of communication networks include a LAN and a
FIG. 5. Consistency rules can then be de?ned to perform the WAN, e.g., the Internet.
consistency checks noted above. The consistency rules can Activities associated with the processes can be rearranged
de?ne state changes in the dependent control cycle caused by and/or one or more such steps can be omitted to achieve the
state sequence couplings. In addition to the actual couplings, 20 same results described herein. All orpart of the processes may
the dependent control cycles can be de?ned in one or more be fully automated, meaning that they operate without user
state sequence coupling matrices. In addition, the state intervention, or interactive, meaning that all or part of the
sequence coupling may de?ne automatic creation of Kanban processes may include some user intervention.
cards. Elements of different embodiments described herein may
Process 800 and any modi?cations or enhancements 25 be combined to form other embodiments not speci?cally set
thereto described above (referred to collectively as “the pro forth above. Other embodiments not speci?cally described
ces ses”) are not limited to use with the hardware and software herein are also within the scope of the following claims.
described above; they may ?nd applicability in any comput What is claimed is:
ing or processing environment and with any type of machine
1. A method of modelling a process chain, comprising:
that is capable of running machine-readable instructions. The 30
mapping processes in the process chain to control cycles;
processes can be implemented in digital electronic circuitry,
designating a control cycle in the process chain to be a
or in computer hardware, ?rmware, software, or in combina leading control cycle;
tions thereof.
designating a control cycle in the process chain to be a
The processes can be implemented via a computer program
product, i.e., a computer program tangibly embodied in an 35
dependent control cycle;
information carrier, e. g., in a machine-readable storage de?ning states for the leading control cycle using a ?rst
device or in a propagated signal, for execution by, or to matrix that de?nes starting and ending states in the lead
control the operation of, data processing apparatus, e.g., a ing control cycle;
programmable processor, a computer, or multiple computers. de?ning states for the dependent control cycle using a
A computer program can be written in any form of program 40
second matrix that de?nes starting and ending states in
ming language, including compiled or interpreted languages, the dependent control cycle; and
and it can be deployed in any form, including as a stand-alone de?ning couplings between states in the leading control
program or as a module, component, subroutine, or other unit cycle and the dependent control cycle to produce a
suitable for use in a computing environment. A computer model of the process chain, at least one of the couplings
program can be deployed to be executed on one computer or 45 causing a state change in the leading control cycle to
on multiple computers at one site or distributed across mul affect a state change in the dependent control cycle;
tiple sites and interconnected by a communication network. wherein the couplings are de?ned using a third matrix that
Actions associated with the processes can be performed by relates the ?rst matrix to the second matrix;
one or more programmable processors executing one or more wherein the at least one of the couplings comprises a one
computer programs to perform the functions of the processes. 50 directional coupling in which the state change in the
The actions can also be performed by, and the processes can leading control cycle affects the state change in the
be implemented as, special purpose logic circuitry, e.g., an dependent control cycle;
FPGA (?eld programmable gate array) and/or an ASIC (ap wherein at least one of the couplings comprises a bi-direc
plication-speci?c integrated circuit). tional coupling in which a state change in the leading
Processors suitable for the execution of a computer pro 55 control cycle or in the dependent control cycle affects,
gram include, by way of example, both general and special respectively, a state change in the dependent control
purpose microprocessors, and any one or more processors of cycle or the leading control cycle; and
any kind of digital computer. Generally, a processor will wherein the third matrix identi?es at least some of the
receive instructions and data from a read-only memory or a couplings as either one-directional or bi-directional.
random access memory or both. Elements of a computer 60 2. The method of claim 1, wherein the third matrix stores
include a processor for executing instructions and one or data indicating whether a state change in a control cycle is a
more memory devices for storing instructions and data. Gen necessary predicate for a state change in another control cycle
erally, a computer will also include, or be operatively coupled or whether a state change in a control cycle can occur inde
to receive data from, or transfer data to, or both, one or more pendently of a state change another other control cycle.
mass storage devices for storing data, e.g., magnetic, mag 65 3. The method of claim 1, wherein the leading and depen
neto-optical disks, or optical disks. Information carriers suit dent control cycles are de?ned in a software system for sup
able for embodying computer program instructions and data porting material ?ow in the process chain.
 US 7,406,358 B2
9 10
4. The method of claim 1, wherein the leading and depen 13. The computer program product of claim 10, Wherein
dent control cycles comprise Kanban control cycles. the leading and dependent control cycles comprise Kanban
5. The method of claim 1, further comprising de?ning a control cycles.
consistency rule, the consistency rule ensuring correct rela 14. The computer program product of claim 10, further
tionships betWeen states in at least one of the dependent comprising de?ning a consistency rule, the consistency rule
control cycle and the independent control cycle. ensuring correct relationships betWeen states in at least one of
6. The method of claim 1, further comprising de?ning an the dependent control cycle and the independent control
error state in at least one of the leading and dependent control cycle.
cycles. 15. The computer program product of claim 10, further
7. The method of claim 6, further comprising linking an comprising instructions that cause the at least one machine to
error state of one control cycle With an error state of another de?ne an error state in at least one of the leading and depen
control cycle. dent control cycles.
8. The method of claim 1, Wherein at least one of the states 16. The computer program product of claim 15, further
is de?ned in at least one Kanban card. comprising instructions that cause the at least one machine to
9. The method of claim 1, Wherein a state sequence is link an error state one control cycle With an error state of
de?ned by at least one set of states of different control cycles another control cycle.
having at least one state coupling type. 17. The computer program product of claim 10, Wherein at
10. A computer program product tangibly embodied in an least one of the states is de?ned in at least one Kanban card.
information carrier, the computer program product compris 18. A system for modelling a process chain, comprising:
ing instructions for use in modelling a process chain, the 20 means for mapping processes in the process chain to con
instructions for causing at least one machine to: trol cycles;
map processes in the process chain to control cycles; means for designating a control cycle in the process chain
designate a control cycle in the process chain to be a lead to be a leading control cycle;
ing control cycle; means for designating a control cycle in the process chain
designate a control cycle in the process chain to be a depen 25 to be a dependent control cycle;
dent control cycle; means for de?ning states for the leading control cycle using
de?ne states for the leading control cycle using a ?rst a ?rst matrix that de?nes starting and ending states in the
matrix that de?nes starting and ending states in the lead leading control cycle;
ing control cycle; means for de?ning states for the dependent control cycle
de?ne states for the dependent control cycle using a second 30 using a second matrix that de?nes starting and ending
matrix that de?nes starting and ending states in the states in the dependent control cycle; and
dependent control cycle; and means for de?ning couplings between states in the leading
de?ne couplings betWeen states in the leading control cycle control cycle and the dependent control cycle to produce
and the dependent control cycle to produce a model of a model of the process chain, at least one of the cou
the process chain, at least one of the couplings causing a 35 plings causing a state change in the leading control cycle
state change in the leading control cycle to affect a state to affect a state change in the dependent control cycle;
change in the dependent control cycle; Wherein the couplings are de?ned using a third matrix that
Wherein the couplings are de?ned using a third matrix that relates the ?rst matrix to the second matrix;
relates the ?rst matrix to the second matrix; Wherein the at least one of the couplings comprises a one
Wherein the at least one of the couplings comprises a one 40 directional coupling in Which the state change in the
directional coupling in Which the state change in the leading control cycle affects the state change in the
leading control cycle affects the state change in the dependent control cycle;
dependent control cycle; Wherein at least one of the couplings comprises a bi-direc
Wherein at least one of the couplings comprises a bi-direc tional coupling in Which a state change in the leading
tional coupling in Which a state change in the leading 45 control cycle or in the dependent control cycle affects,
control cycle or in the dependent control cycle affects, respectively, a state change in the dependent control
respectively, a state change in the dependent control cycle or the leading control cycle; and
cycle or the leading control cycle; and Wherein the third matrix identi?es at least some of the
Wherein the third matrix identi?es at least some of the couplings as either one-directional or bi-directional.
couplings as either one-directional or bi-directional. 50 19. The system of claim 18, Wherein the leading and depen
dent control cycles are de?ned in a softWare system for sup
11. The computer program product of claim 10, Wherein
the third matrix stores data indicating Whether a state change
porting material How in the process chain.
in a control cycle is a necessary predicate for a state change in 20. The system of claim 18, Wherein the leading and depen
another control cycle or Whether a state change in a control
dent control cycles comprise Kanban control cycles.
55 21. The system of claim 18, Wherein the third matrix stores
cycle can occur independently of a state change another other
data indicating Whether a state change in a control cycle is a
control cycle.
necessary predicate for a state change in another control cycle
12. The computer program product of claim 10, Wherein
or Whether a state change in a control cycle can occur inde
the leading and dependent control cycles are de?ned in a
pendently of a state change another other control cycle.
softWare system for supporting material How in the process
chain. * * * * *