Production Control

The ongoing development of Radio Frequency Identification (RFID) opens up new possibilities to parallelize information and material flows. Manufacturing processes can be provided with real time information and new lifecycle services (e.g. definition of optimal cutting parameters, life cycle data, etc.) can be realized. In this paper the advantages of RFID on metal cutting tools are discussed. RFID on tools can support an efficient tool management and help to automate manual activities within the manufacturing process.

The continuously growing cost pressure, individual production orders as well as decreasing innovation cycles are only a few characteristics of the vital structural change that the production industry has been confronted with during the past years. In order to stand out against the competitors and to gain an advantage in competition, an enterprise has to have the ability to adjust to the dynamic demands of the internal and external environment. A contribution to that is a flexible control system for the material flow. This article presents a heuristic based algorithm for the hot rolling production scheduling problem of a steel manufacturer.

In recent years dynamics in the automotive industry has increased rapidly. Beside a higher degree of customer orientation product life cycles become continuously shorter, whereby an over-all effect on Ramp-up and Phase-out Management can be stated. Because of an increasing amount of new model ranges Ramp-up Management has been well discussed during the last few years. In contrast, discussions about an efficient Phase-out Management are mostly still missing. This paper presents an approach focusing on the transparency of information considering the requirements of Production Phase-outs.

A simple production system enables to customer oriented manufacturing with low cost and high costumer service. The most four important ways to a simple production are covered by: • Reduction of the number of items (finished goods, intermediate as well as purchasing parts) • Setting of clear and non-conflicting objectives as well as prioritizing measurements needed • Organizing of a continuous production flow and • Applying monitoring instruments instead of detailed planning and scheduling tools

With the implementation of numerous modernization concepts an increasingly complicated system has emerged in the companies. Single concepts partly overlap or redundantly pursue similar targets under different headings. Some concepts even compete in their target dimensions. The tool Independencies Map systematically analyzes the correlation of existing concepts and searches for inconsistencies and incompatibilities between these concepts. This article presents a pragmatic tool, which is also applicable for small and medium enterprises thus enabling them to remove efficiency barriers by harmonizing the interaction of the individual concepts.

This paper discusses ideas about and experiences with flexible simulation of real-time data streams generated by production networks when state-of-the-art automatic identification and localization technologies are applied. Flexibility here means the possibility to freely define the objects and their related types of events and statuses that are recorded in production and logistics processes. The data streams generated during simulation can be used to test and compare operational control strategies for processes in production networks in an offline or online mode.

In an increasingly turbulent environment, convincing methods of production planning and control are needed. Many of the necessary decisions are made at shop-floor-level. They depend on the knowledge and the abilities of the workers to react on unpredictable impact and hence are not explicitly described. For a realistic, concomitant plant simulation, however, it is important, to model the control strategies as exactly as possible. This paper presents a method to identify applied control strategies by adopting artificial neural networks to data from the operating and machine data logging.

The strategically appropriate dimensioning of inventory in the process chain is of utmost importance for companies. In this context inventory is utilized to counterbalance variations of the behaviour of customers as well as delivery date or quantity deviations caused by suppliers. It is a huge challenge to dimension the inventory as to realize a high level of security but also low stocks. This article demonstrates the methodical approach, the outcome of the Logistic Stock Analysis, and the validation of planning methods showcased for a project at the electronic factory of Siemens, Amberg.

Actually there are existing significant deficits in the information flow along the NC process chain. The deficits are solved insufficient by introducing CAD-CAM systems and feature-oriented specification languages, because of the usage of the DIN 66025 as NC programming language. In contrast to that the application of new production technologies (like laser treatments) requires a high quantity and quality of information from the planning phases in the shop floor in order to compensate the relatively small collected wealth of experience with these technologies. A guidance system offers the machine operator now the possibility to access additional planning data. Thus it is possible, that new collected experience by setting up a NC program can be stored and reused in order to avoid repetitive errors in the numerical control procedure chain.

Today, globalization is on the top of CEO’s agenda. Both, the unparalleled potential to grow into new markets as well as boosting the competitiveness of production are great opportunities making the globalization of production an imperative for successful companies. However, the risk and the complexity of that task require a dedicated approach to design, implement and manage the company’s network. Therefore, the article describes a basic project concept, major milestones and a promising scope of action for global production management.