Manufacturing Systems

Processing of the production orders in sync with customer demand, on schedule, at short notice, with constant machine utilization, is the vision of many a plant manager. Besides machine and personnel productivity, stock volume is for this the clearest performance indicator. In large-scale production, this vision has quite successfully been approached through assembly lines with a continuous, pulled material flow and one-piece production. Especially in series and small series production with high variety, however, the same concepts are not applicable or not very successful. A sustainable way to approach the vision in such a setting is described in this paper based on the practical example of TRUMPF Grüsch AG.

Lot sizing is a substantial factor of economic production. There are various lot sizing approaches considering the same cost factors in different ways. Their results are usually quite similar. A common weakness of all lot sizing approaches is the limited consideration of relevant cost factors. The costs which are neglected usually rise with increasing lot sizes. This leads to illusory exact results because too large lots are calculated generally. This paper compares functions and results of different lot sizing approaches and discusses neglected cost factors.

In today’s business environment enterprises react to changing conditions with the implementation of Lean Production Systems (LPS). But changing conditions are not only effecting the production. The role of product development is becoming increasingly important to the overall business success. Many enterprises react by designing specific Lean Development concepts. As there are different approaches to design concepts, enterprises have to decide which approach to follow. This paper presents the approach, which takes LPS as the basis, considering the circumstances of the development process and transfers it to the development process to design a Lean Development concept. It is demonstrated how the transfer of the LPS-principles based on VDI 2870 would affect the development process.

In the field of automobile production, automation has been implemented since the nineteen-seventies. In logistics, however, robotics has only been used to automate logistics processes with low complexity. These include processes with a high repetition rate and a highly standardized goods portfolio. In cooperation with EASY-ROB, BIBA has developed a new strategy for an intuitive programming of robotics that might be used to fulfill rather complex tasks. The operator defines the process type and important parameters via a common tracking system. Based on this data, a simulation tool calculates the movement of the robot and executes a collision control. Finally, the simulation tool generates the corresponding machine code and the robot starts its process. The intuitive programming excels at a favorably cost-benefit ratio. A demonstrator, focusing on the unloading of pallets has been presented on the CeMAT 2011. After a very brief introduction, interested visitors were able to operate the ...

Sustainability in lean production systems arises when the relevant lean principles are addressed by preferably all stakeholders in the context of permanent improvement processes. For this purpose a skills development of all employees is necessary, even for managers, as they convey the CIP position by their people skills and set an example. If this succeeds, improvement processes will develop into a sustainable learning process, which in turn serves as a self-reinforcing factor for the further development of staff skills. An approach to skills development and to the corresponding leadership system for improvement processes is presented and supported by preliminary results of an empirical study.

Due to the concentration of core competences and the utilisation of international location advantages successful German production companies face a situation with globally dispersed sites in global value added networks. The ongoing globalisation, which includes the integration of external sites, suppliers and partners, leads to complex interactions within networks. However, these interactions are not or are simply partially known and not predictable so far. Being able to control dramatic dynamics in the behaviour of global value added networks, German production companies will be positively affected by globalisation in the future. Therefore, changeable global value added networks which can be quickly adjusted to dynamics become crucial. The paper on hand describes an approach for the planning and optimization of adaptable global value added networks. Background is the approach of the research project “planning and optimization of changeable global value added networks” (POWer.net) ...

Production systems require a continuous development to contribute to the competitiveness of the manufacturing industry. Therefore, the audit of production systems enables the determination of the current maturity level of production. This allows for the identification of deficits and the definition of starting points for a sustainable optimization of the production. This article focuses on the development of a maturity level based self-assessment concept for the evaluation of the sustainability of production systems.

Due to a difficult market situation represented by the world economic and related market crisis and a steady growth of model-variety the automotive industry is facing major challenges: short innovation cycles, increased complexity of production and cost pressures. To respond to these challenges advanced approaches for long-term planning of production systems have to be implemented. This paper presents approaches of plant design utilizing digital factory and shows applications of operations research (OR) for the planning of production systems. The application of OR methods holds significant potential not only for the network planning level but also for supporting strategic decisions on the production system level.

For the design of an agile production system in addition to the holistic view of production and its internal and external links, a detailed analysis of individual components is necessary. These elements are general manufacturing equipment in various types of expression. To investigate and valuate the properties of these components primarily key figures and indicators are used. In the field of facility and maintenance management the Overall Equipment Effectiveness (OEE) parameter is widely used to determine the equipment efficiency. This indicator is an integral part of a holistic maintenance management. Recent developments use the OEE value as a basis to evaluate the whole value chain to get a holistic view of the included equipment. This integrated approach is an essential component for assessing the flexibility of production systems, which presents itself in three different dimensions.

Nowadays, companies are facing a rapidly changing environment. New products have to be integrated into established manufacturing processes at ever shorter intervals. To assure competitiveness the design of changeable production systems gains more and more importance. Therefore, a control loop of changeability has been developed within the research project “change-supporting process architectures”. The control loop empowers companies to identify urgent changeability needs with an evaluation method and helps them to design and use change-supporting process architectures with economical solutions. The presented article focuses on the methodology for the evaluation of changeability.