production system

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.

Companies nowadays face a plethora of challenges such as ever increasing customer requirements, globally distributes production networks or changing product life cycles. In order to react appropriately to these turbulences, production systems can be designed changeable. Today’s solutions often do not suffice. In particular, the needed time and the necessary extent of change are identified only intuitively. In this paper is presented a control-loop-based synchronization approach, which allows carrying out the change in the right quantity at the right time. An application example will further the theoretical bases.

To compete in the global environment companies in high wage countries have to separate themselves from competitors from low wage countries by offering customer specific products and services. Due to the rising complexity of these products the steering of the corresponding production systems is getting more and more resource consuming. One way to handle this aspect is developed within the Excellence Cluster “Integrative production technology for High-wage countries” at RWTH Aachen University. Objective is the set up of production systems that are able to produce customer specific products at mass production costs.

Developing and testing and operating complex machinery and repairing it under time pressure if it breaks down - individuals in many professions have to learn new skills. Moreover, they have to do so as quickly and as thoroughly as possible. Virtual technologies are supporting learning more and more frequently. Operations and procedures on machinery and plants are already taught in individual lessons on the virtual model. They can be repeated as often as desired without the space or time constraints of real machinery and without endangering either operator or plants through incorrect behaviour and can be practiced before a real machine or plant has been constructed.

Complex production systems in micro production, concerning the manufacturing of miniaturised systems, assemblies and components, are very special. For example Hesselbach [1] stated, that micro production technology (sometimes to be found as (ultra) precision engineering) spans basically all, partly highly specialised production techniques. Kiesewetter [2] points out, that micro production is not just a kind of “shrinked machine building or mechanical engineering”. Mostly the whole manufacturing process chain or at least larger, interrelated section or subsystems and -processes, for example mainly for the manufacturing of miniaturised mechanical modules or assemblies respectively, are basically not examined. The paper discusses and presents topics concerning the planning and operations of micro production manufacturing process chains, against the background of the manufacturing of miniaturised mechanical modules and components.

The ramp-up of a production system is a part of the product creation process. In a highly dynamic and complex sur-rounding, it is more then every other phase characterised by an immediate call for action. This challenge can be met by designing production systems in a way that they offer a maximum of flexibility and transparency. In this context, planning a robust ramp-up means designing production systems that are flexible enough to balance transient state working systems and that are easy to handle in order to achieve a steep learning curve. How this can concretely be implemented, which are the benefits of the actual planning methods and -tools for the production, and what a company has to do to tap the full potential is demonstrated at two examples from the automotive supply industry.

Due to shortening product life cycles and to the continuous enlargement of product ranges the ramp-up of production systems has become a significant criterion for innovation dynamics of producing companies. Besides the in-creasing technical complexity, a growing number of different parties are involved with different targets and interests. The result is a rising number of possible disturbances for the ramp-up process. In order to better control and shorten ramp-up projects, methods and tools have to be developed to manage the project along the complete value chain. The article gives an outlook on the ramp-up of the future by describing an approach that is the basis for a research project supported by the German ministry of research and education.