Towards a decision-support framework for reducing ramp-up effort in plug-and-produce systems

Nowadays, shorter and more flexible production cycles are vital to meet the increasing customized product demand. As any delays and downtimes in the production towards time-to-market means a substantial financial loss, manufacturers take an interest in getting the production system to full utilization as quickly as possible. The concept of plug-and-produce manufacturing systems facilitates an easy integration process through embedded intelligence in the devices. However, a human still needs to validate the functionality of the system and more importantly must ensure that the required quality and performance is delivered. This is done during the ramp-up phase, where the system is assembled and tested first-time. System adaptations and a lack of standard procedures make the ramp-up process still largely dependent on the operator’s experience level. A major problem that currently occurs during ramp-up, is a loss of knowledge and information due to a lack of means to capture the human’s experience. Capturing this information can be used to facilitate future ramp-up cases as additional insights about change actions and their effect on the system could be revealed. Hence, this paper proposes a decision-support framework for plugand-produce assembly systems that will help to reduce the ramp-up effort and ultimately shorten ramp-up time. As an illustrative example, a gluing station developed for the European project openMOS is considered

Propuesta de adaptación del sistema de producción de serie a régimen a la fase de escalada de producción de un nuevo modelo en el sector de automoción

La industrialización de la producción de un nuevo modelo en el sector de la automoción es un proceso que conlleva grandes inversiones en medios productivos, los cuales deben de estar preparados para producir en el momento del inicio de la fabricación en serie del mencionado nuevo modelo (SOP Start of production). A partir de este momento el alcanzar la producción de régimen según la curva planificada (curva de escalada) es el objetivo principal de toda la organización. A lo largo de la historia se repiten lanzamientos que no consiguen alcanzar los objetivos de volumen de producción, plazos de entrega, calidad del producto y en definitiva los costes planificados. Este suceso ha sido ampliamente estudiado, pero es en los últimos 10 años cuando más interés ha suscitado impulsado por la reducción de los ciclos de vida de los productos y en consecuencia el creciente aumento de los lanzamientos de nuevos modelos. A través de metodologías cuantitativas y cualitativas, esta tesis contribuye a paliar este problema presentando dos propuestas complementarias. La primera de ellas ha resultado de la aplicación de la metodología “Action Research” realizada en una importante empresa fabricante de automóviles de la que se concluyó la necesidad de la creación y organización de equipos de mejora específicos para el lanzamiento. Al comparar las condiciones de contorno de la fábrica durante las fases de escalada y serie se aprecian diferencias importantes tanto en material en flujo (WIP) como en la frecuencia y gravedad de los problemas aparecidos diariamente de tal forma que finalmente esta tesis reconoce a la época de escalada como un estadio diferenciado del ciclo de vida del modelo debiendo ser aplicado un sistema de producción (PS) diferenciado al habitual de la producción en serie. El hecho de que el estudio “Action Research” ha sido realizado en una única fábrica de un solo modelo, limita los resultados a esa tipología de fábrica, no por ello dejando de ser interesantes. La segunda propuesta está relacionada con la posibilidad de definir unos almacenes intermedios óptimos para la época de la escalada diferentes a los establecidos para la producción a régimen. En este segundo caso la metodología elegida ha sido la simulación discreta. A pesar de las limitaciones del estudio, los resultados presentados serán de gran interés tanto para profesionales del sector de la automoción y de otros sectores que tengan que incrementar los lanzamientos de nuevos productos, así como para académicos. Desde el punto de vista académico la tesis trata el problema de lanzamientos de nuevos modelos analizando de una forma global la aplicación del sistema de producción como posible causa de la aparición de los problemas durante esta fase. Desde el punto de vista práctico, el contenido de esta tesis puede ayudar a entender algunos de los factores que explican por qué los objetivos de calidad y producción no son obtenidos durante esta fase. En resumen, esta tesis presenta un enfoque innovador para entender y manejar la problemática de los lanzamientos de los nuevos modelos bajo el prisma de la aplicación del sistema de producción (PS). Dado que los resultados de la tesis están contrastados en una fábrica de un solo modelo queda abierta la investigación futura en el caso de fábricas de más de un modelo.The industrialization of the production of a new model in the automotive sector is a process that entails large investments in production means, which must be prepared to produce at the time of the start of serial production of the aforementioned new model (SOP Start of production). From this moment on, reaching the summit-production according to the planned curve (ramp-up curve) is the main objective of the entire organization. Throughout history, launches have been repeated that fail to achieve the objectives of production volume, delivery times, product quality and, ultimately, planned costs. This event has been widely studied, but it is in the last 10 years when it has aroused the most interest, driven by the reduction of the life cycles of the products and consequently the increasing in the launches of new models. Through quantitative and qualitative methodologies, this thesis contributes to alleviating this problem by presenting two complementary proposals. The first of these has resulted from the application of the “Action Research” methodology carried out in a major automobile manufacturer company, which concluded the need for the creation and organization of specific improvement teams for the launch. When comparing the contour conditions of the factory during the ramp-up and series phases, important differences are appreciated. Both in material in flow (WIP) and in the frequency and severity of the problems that appear daily in such a way that finally this thesis recognizes the ramp-up phase as a differentiated stage of the life cycle of the model. A production system (PS) differentiated from the usual one of series production must be applied. The fact that the “Action Research” study has been carried out in a single factory with a single model, limits the results to that type of factory, but is nonetheless uninteresting. The second proposal is related to the possibility of defining optimal intermediate buffers for the ramp-up phase, different from those established for regime production. In this second case, the methodology chosen has been the discrete simulation. Despite the limitations of the study, the results presented will be of great interest both to professionals in the automotive sector and from other sectors who have to increase the launches of new products, as well as for academics. From an academic point of view, the thesis deals with the problem of launching new models, analyzing in a global way the application of the production system as a possible cause of the appearance of problems during this phase. From a practical point of view, the content of this thesis can help to understand some of the factors that explain why the quality and production objectives are not obtained during this phase. In summary, this thesis presents an innovative approach to understand and handle the problem of new model launches from the point of view of the application of the production system (PS). Given that the results of the thesis are contrasted in a factory with a single model, future research is open in the case of factories with more than one model

Design and application of the software for systematic approach of the products and services developments

Orientador: Franco Giuseppe DediniTese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia MecanicaResumo: Neste trabalho é proposto um estudo que tem como objetivo demonstrar a aplicabilidade da metodologia de projeto, para segmentos de produtos e serviços. A criação de novos produtos implica em uma elevada probabilidade de insucesso. Técnicas que permitam reduzir o tempo de desenvolvimento de projeto, com maior eficiência e que sejam sistematizadas são altamente indicadas, para projeto e melhorias de produtos e serviços. Neste contexto, a metodologia de projeto apresenta uma série de ferramentas e técnicas que podem nortear os objetivos desejados. Para o estudo de caso em serviços, a metodologia de projeto foi utilizada no desenvolvimento de novos produtos, através de um programa (ProCria) e Guia Rápido de Projeto, que são procedimento de boas praticas de projeto. Dessa forma, foi possível apresentar e avaliar esse processo sistemático, com os usuários do programa que certamente poderão difundir a importância da metodologia de projeto no desenvolvimento de produtos. Como resultado deste trabalho é apresentado a metodologia proposta, na qual são apresentadas as etapas de projeto para o desenvolvimento de produto com uma linguagem mais acessível e evidenciando a utilidade da metodologia.Abstract: The creation of new products implies in one high probability of failure. Techniques to provide a project development time reduction with more efficiency and systematically are highly indicated for project and for products and services improvements. In this context, the project methodology presents a series of tools and techniques which can guide the intended objectives. This work proposed a study that aims to demonstrate the applicability of the project methodology to products and services segments. For the case study in services, the project methodology was used in the new products development, through Software and Fast Guide of Project, that were created for this purpose. Thus, it was possible presents and evaluates this systematic process, with the software users who certainly will be able to spread out the importance of the project methodology in the products development. As result of this work is presented the purpose methodology, in which the project stages for the product development are presented with a accessible language and evidencing the methodology utility.DoutoradoMecânica dos Sólidos e Projeto MecânicoDoutor em Engenharia Mecânic

The Role of Lean and Agile Logistics during Production Ramp-Up

In addition to the rareness of theoretical and empirical research, which extends to every aspect of the production ramp-up literature, the increasing importance of the ramp-up phase – due to the continuously decreasing product lifecycle in almost all industrial sectors –magnifies the need for more research efforts in this field. Based on a comprehensive literature review, no attempts to investigate the role of lean and/or agile logistics during the ramp-up stage were found. Utilizing the survey method, this research empirically explores the effects of lean and agile logistics on production performance during the ramp-up phase in terms of quantity, quality, and cost. A special purpose questionnaire was developed to collect primary data based on a literature review in the fields of production ramp-up, lean logistics, lean production, agile logistics, agile production, performance measurement, and product success. The measurement model was evaluated for validity and reliability and tested for temporal consistency and the existence of common method variance; the collected data were tested for measurement and non-response biases; and the results were evaluated for their statistical power and statistical conclusion error. Out of 63 questionnaires collected from industrial organizations operating in 7 countries and in different sectors, 56 responses were used in the statistical analyses. A two-step methodological approach was utilized in the data analysis. In the first step, the data collected on the research variables were analysed following a theory confirmation procedure to examine the validity of a hypothesized positive effect of lean and agile logistics on ramp-up performance. In addition, the effect of ramp-up performance on new products’ success, the moderating effect of some respondent, organizational, and product-related variables, and the mediating effect of outbound logistics were investigated. The partial least squares method of structural equation modelling (PLS-SEM) was employed during the confirmatory analysis. Different scenarios were evaluated to test the main and subsidiary hypotheses proposed, based on the use of formative and reflective measures and first- or higher-order variable formats. The results of the confirmatory data analysis supported the hypothesized positive effect of lean and agile logistics on production performance during the ramp-up phase. In the second methodological step, exploratory analyses were conducted to explore further patterns in the data collected. Correlation matrices indicated a greater effect of agility on quantity performance and a greater effect of leanness on cost performance. Such trends are generally accepted and supported by the theoretical literature and by practitioners. However, the agreed-upon priorities of time reduction during the ramp-up phase and cost reduction during the steady-state and ramp-down phases motivated the proposition of a mixed model that uses higher levels of agility throughout the ramp-up phase and higher leanness levels thereafter. The proposed mixed system was supposed to outperform the pure lean, pure agile, and leagile strategies. Among the methods proposed to apply such a mixed production system, the development of a specialized agile ramp-up facility was introduced. It was suggested that all products undergoing a ramp-up phase should be produced with an agile system, in a specialized ramp-up facility, and then moved to a lean facility during the steady-state and ramp-down production phases. To examine the feasibility of the proposed system and the magnitude of investment that might be accepted to gain the expected enhancement, the total lifecycle profitability of each system – lean, agile, leagile, and mixed – was calculated and compared to provide insights into the advantages of the mixed system and the conditions that increase or decrease the appeal of investing in such a strategy. It was concluded that the adoption of the proposed system and the asset investment magnitude should be evaluated considering different possible combinations of the product’s type, price, cost, contribution, and lifecycle length, among other variables. The proposed system has been proven to be more attractive to adopt as the proportion of the ramp-up time to the total lifecycle increases, as the product’s price drops faster, as the peak sales are reached earlier, or as the number of ramp-ups increases

Acquisition and sharing of innovative manufacturing knowledge for preliminary design

This study investigates the identification, acquisition and sharing of innovative manufacturing knowledge for the preliminary design of complex mechanical components. Such components need to satisfy multiple, often conflicting design and performance requirements. Some degree of innovation may be required, involving the development of new manufacturing processes. The innovative nature of this manufacturing knowledge makes it difficult to define, codify and share, especially during preliminary design, where this can present significant risks in the design process. Current methods of knowledge sharing do not account for the immature nature of innovative manufacturing knowledge and the combined explicit and tacit elements needed to express it. A flexible interpretive research study with inductive and hypothesis testing elements was undertaken to explore this novel knowledge management problem. During the inductive phase, two data collection activities were undertaken to investigate the manufacturing knowledge required for the preliminary design of gas turbine engines. Using a data driven approach, the main findings which emerged were: the need to include an assessment of the maturity of the design process; the need to use a range of tacit and explicit knowledge to effectively share this and the need to manage knowledge across different domain boundaries. A conceptual framework of the findings was used to develop a hypothesis of knowledge requirements for preliminary design. For the hypothesis testing phase, a systematic methodology to identify, acquire and share innovative manufacturing knowledge for preliminary design was developed from the knowledge requirements. This approach allowed both explicit and tacit knowledge sharing. An evaluation of the methodology took place using three different industrial cases, each with a different component / manufacturing process. The evaluations demonstrated that using the range of knowledge types for transferring knowledge was effective for the specific cases studied and confirmed the hypothesis developed.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Towards an integrated framework for the configuration of modular micro assembly systems

The future of manufacturing in high-cost economies is to maximise responsiveness to change whilst simultaneously minimising the financial implications. The concept of Reconfigurable Assembly Systems (RAS) has been proposed as a potential route to achieving this ideal. RASs offer the potential to rapidly change the configuration of a system in response to predicted or unforeseen events through standardised mechanical, electrical and software interfaces within a modular environment. This greatly reduces the design and integration effort for a single configuration, which, in combination with the concept of equipment leasing, enables the potential for reduction in system cost, reconfiguration cost, lead time and down time. This work was motivated by the slow implementation of the RAS concept in industry due, in part, to the limited research into the planning of multiple system reconfigurations. The challenge is to enable consideration of, and planning for, the production of numerous different products within a single modular, reconfigurable assembly environment. The developed methodology is to be structured and traceable, but also adaptable to specific and varying circumstances. This thesis presents an approach that aims towards providing a framework for the configuration of modular assembly systems. The approach consists of a capability model, a reconfiguration methodology and auxiliary functions. As a result, the approach facilitates the complete process of requirement elicitation, capability identification, definition and comparison, configuration analysis and optimisation and the generation of a system configuration lifecycle. The developed framework is demonstrated through a number of test case applications, which were used during the research, as well as the development of some specific technological applications needed to support the approach and application

Towards an integrated framework for the configuration of modular micro assembly systems

The future of manufacturing in high-cost economies is to maximise responsiveness to change whilst simultaneously minimising the financial implications. The concept of Reconfigurable Assembly Systems (RAS) has been proposed as a potential route to achieving this ideal. RASs offer the potential to rapidly change the configuration of a system in response to predicted or unforeseen events through standardised mechanical, electrical and software interfaces within a modular environment. This greatly reduces the design and integration effort for a single configuration, which, in combination with the concept of equipment leasing, enables the potential for reduction in system cost, reconfiguration cost, lead time and down time. This work was motivated by the slow implementation of the RAS concept in industry due, in part, to the limited research into the planning of multiple system reconfigurations. The challenge is to enable consideration of, and planning for, the production of numerous different products within a single modular, reconfigurable assembly environment. The developed methodology is to be structured and traceable, but also adaptable to specific and varying circumstances. This thesis presents an approach that aims towards providing a framework for the configuration of modular assembly systems. The approach consists of a capability model, a reconfiguration methodology and auxiliary functions. As a result, the approach facilitates the complete process of requirement elicitation, capability identification, definition and comparison, configuration analysis and optimisation and the generation of a system configuration lifecycle. The developed framework is demonstrated through a number of test case applications, which were used during the research, as well as the development of some specific technological applications needed to support the approach and application