Thema: Lean Production

There are numerous analysis methods available to support engineers working on continuous improvement projects. Digital transformation facilitates to reduce the effort for data acquisition and processing. The Institute of Production Management and Technology and the medical company Dräger have jointly developed a web application for multi-method analysis. This article describes its data structure and technology.

There is a variety of empirically validated methods for implementing pull-systems in the manufacturing industry, but pull-based replenishment for the process industry remains a research gap. This article describes the development of a model for implementing a pull-system for an intracompany production network in the process industry and its validation in a case company.

Due to the rapid development in information technologies, the amount of information production staff has to deal with rises. Additionally, the requirements for the changeability and flexibility of control systems are growing. This leads to a constantly growing complexity in the handling of information. By avoiding unnecessary information logistics processes, this complexity is reduced and information management becomes easier.

Volatility in market demand leads to temporary over- and under utilization of productive assets. Heijunka aims at de-coupling the production system from market volatility. The production program is spread as even as possible over time. This achieves high asset utilization, short lead times, and low inventories. There are validated Heijunka methods for the manufacturing industry, but for the process industry this remains a research gap. This article describes the development of a Heijunka model for the process industry in order to close that gap.

An actual study about the implementation of holistic production systems in small and medium-sized enterprises (SMEs) illustrates the desire of most SMEs to realize a clearly structured and high performance production. The study shows up great difficulties due to lack of methodological expertise in the context of a production system implementation [1]. For this reason, the University of Applied Sciences Landshut developed a framework for methods which is part of the “Landshuter Produktionssystem (LPS): CLean Production - Lean & Clean”. The ‘methods-wheel’ concept enables the comprehensible, systematic and complete presentation of all necessary methods and tools for the LPS. Thus, the situational correct selection of methods is facilitated as well as the desired clarity and transparence is given. By integrating the methods-wheel in the overall context of the LPS interactions between goals, principles, methods and operational processes will be illustrated. As a consequence, the ...

An actual study about potentials and needs of action in the range of factory planning projects shows clearly that the used process models can’t handle the dynamic and the complexity in these projects. For this reason, the University of Applied Science Landshut has been developing within the Landshuter Produktionssystem (LPS): CLean Production - Lean & Clean a new factory planning methodology. This allows for the first time to design the factory structures from beginning based on lean criteria in connection with the planning and control. The method will also satisfy the requirements referred because of an agile process model.

For a sustained improvement in the logistic goals, such as the punctuality of delivery or cycle time, a consistent, process-oriented design, planning and execution of production systems is required. Besides the development of new methods, support by appropriate IT systems is necessary. Especially for SMEs, there are no solutions in this regard. Thereby first of all the existing MRP systems remain in the old thought patterns, to control and regulate the complexity of the real world through a detailed illustration as a model. For the development of a new ppc system the customer needs were determined apart from solutions of existing systems. The article shows the “real” needs in the environment of the factory structure design and production planning and control of SMEs by using innovation management according to Design for Six Sigma+Lean (DFSS+Lean).

Due to an increasing cost pressure especially big companies decided in recent years to implement a lean production system. However, the majority does not meet their expectations regarding the overall performance. An actual study confirms the companies´ dissatisfaction. There is a lack of structured and systematic approaches for lean production. Especially small and midsized companies ask for a systematic description for the concept in order to understand the context and to get a guideline for the implementation.