Production Control

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.

The goal of the following article is to introduce a new work sampling estimation procedure along with a usage example, as well as to contrast these with the previous procedure. The new procedure enables the gradual estimation of portions of procedure types without iteration loops. In addition, it also delivers precise estimated values and can consistently process a priori information in small random samples. Furthermore, through visualization, additional decision support about the so-called probability density functions is made available for the industrial engineer in the business.

In cooperation with seven industrial enterprises of different branches the institute of Production Systems and Logistics developed in the course of a research project an IT-System for the Logistic Controlling of Production Processes. The project was funded by the Stiftung Industrieforschung. The IT-System supports logisticians of enterprises by the logistic controlling of production processes and by associated planning and design of improvements.

Today, excellence in production planning and control (PPC) is not only critical for the success of enterprises it is rather a strategic factor of competitiveness. Particularly in job shop manufacturing lot sizing is a vitally important function of PPC, due to its influence on the necessary positioning between manufacturing efficiency on the one hand and flexibility on the other hand. The article shows by example of a project of the IFA and the proIng GbR in cooperation with an automotive components supplier, that the development of a concept for effective an efficient lot sizing requires in addition to the selection of the suitable method a logistical analysis and classification of the products.