Order fulfillment in high variety production environments

Providing high levels of product variety and product customization is challenging for many companies. This paper presents a new classification of production and order fulfillment approaches available to manufacturing companies that offer high variety and/or product customization. Six categories of approaches are identified and described. An important emerging approach - open pipeline planning – is highlighted for high variety manufacturing environments. It allows a customer order to be fulfilled from anywhere in the system, enabling greater responsiveness in Build-to-Forecast systems. The links between the open pipeline approach, decoupling concepts and postponement strategies are discussed and the relevance of the approach to the volume automotive sector is highlighted. Results from a simulation study are presented illustrating the potential benefits when products can be reconfigured in an open pipeline system. The application of open pipeline concepts to different manufacturing domains is discussed and the operating characteristics of most relevance are highlighted. In addition to the automotive, sectors such as machinery and instrumentation, computer servers, telecommunications and electronic equipment may benefit from an open pipeline planning approach. When properly designed these systems can significantly enhance order fulfillment performance

Innovative configurable and collaborative approach to automation systems engineering for automotive powertrain assembly

Presently the automotive industry is facing enormous pressure due to global competition and ever changing legislative, economic and customer demands. Both, agility and reconfiguration are widely recognised as important attributes for manufacturing systems to satisfy the needs of competitive global markets. To facilitate and accommodate unforeseen business changes within the automotive industry, a new proactive methodology is urgently required for the design, build, assembly and reconfiguration of automation systems. There is also need for the promotion of new technologies and engineering methods to enable true engineering concurrency between product and process development. Virtual construction and testing of new automation systems prior to build is now identified as a crucial requirement to enable system verification and to allow the investigation of design alternatives prior to building and testing physical systems. The main focus of this research was to design and develop reconfigurable assembly systems within the powertrain sector of the automotive industry by capturing and modelling relevant business and engineering processes. This research has proposed and developed a more process-efficient and robust automation system design, build and implementation approach via new engineering services and a standard library of reusable mechanisms. Existing research at Loughborough had created the basic technology for a component based approach to automation. However, no research had been previously undertaken on the application of this approach in a user engineering and business context. The objective of this research was therefore to utilise this prototype method and associated engineering tools and to devise novel business and engineering processes to enable the component-based approach to be applied in industry. This new approach has been named Configurable and Collaborative Automation Systems (CO AS). In particular this new research has studied the implications of migration to a COAS approach in terms of I) necessary changes to the end-users business processes, 2) potential to improve the robustness of the resultant system and 3) potential for improved efficiency and greater collaboration across the supply chain... cont'

Sustainability in the Aerospace, Naval, and Automotive Supply Chain 4.0: Descriptive Review

The search for sustainability in the Supply Chain (SC) is one of the tasks that most concerns business leaders in all manufacturing sectors because of the importance that the Supply Chain has as a transversal tool and due to the leading role that it has been playing lately. Of all the manufacturing sectors, this study focuses on the aerospace, shipbuilding, and automotive sectors identified as transport. The present study carries out a descriptive review of existing publications in these three sectors in relation to the sustainability of the Supply Chain in its 4.0 adaptation as an update in matters that are in constant evolution. Among the results obtained, Lean practices are common to the three sectors, as well as different technologies focused on sustainability. Furthermore, the results show that the automotive sector is the one that makes the greatest contribution in this sense through collaborative programs that can be very useful to the other two sectors, thus benefiting from the consequent applicable advantages. Meanwhile, the Aerospace and Shipbuilding sectors do not seem to be working on promoting a sustainable culture in the management of the Supply Chain or on including training programs for their personnel in matters related to Industry 4.0

A literature review and Research Agenda of Value Stream Mapping addressing Study Population and Sample Design

The Purpose of this literature review is to provide a taxonomy of value stream mapping research and, based on that, to develop a research agenda for this field of study in relation to study population and research design. The proposed value stream mapping research classification framework is based on a comprehensive literature review, which concentrates on peer-reviewed journal papers published within the period 2002-2020. A total of 83 academic sources have been retrieved and analyzed interms of research purpose and nature, methodology employed, theoretical approach and level of analysis. The review reveals that value stream mapping research is empirical-descriptive in nature and that it generally lacks a sampling design foundation and a tin study population. It identifies certain knowledge gaps and develops sixe propositions for future research. It suggests that focus should be directed towards more conceptual model, mathematical model, interviews, empirical triangulation (mixed methods) and simulation based studies. It also argues that further empirical research in relation to value stream mapping in relation to study population and sample design needed. This paper fulfils an identified need for a comprehensive classification framework of value stream mapping studies. It essentially provides both academics and practitioners with a conceptual map of existing value stream mapping research and also points out opportunities for future research

Set-Based Concurrent Engineering Model for Automotive Electronic/Software Systems Development

Organised by: Cranfield UniversityThis paper is presenting a proposal of a novel approach to automotive electronic/software systems development. It is based on the combination of Set-Based Concurrent Engineering, a Toyota approach to product development, with the standard V-Model of software development. Automotive industry currently faces the problem of growing complexity of electronic/software systems. This issue is especially visible at the level of integration of these systems which is difficult and error-prone. The presented conceptual proposal is to establish better processes that could handle the electronic/software systems design and development in a more integrated and consistent manner.Mori Seiki – The Machine Tool Compan

Development of a toolkit for component-based automation systems

From the earliest days of mass production in the automotive industry there has been a progressive move towards the use of flexible manufacturing systems that cater for product variants that meet market demands. In recent years this market has become more demanding with pressures from legislation, globalisation and increased customer expectations. This has lead to the current trends of mass customisation in production. In order to support this manufacturing systems are not only becoming more flexible† to cope with the increased product variants, but also more agile‡ such that they may respond more rapidly to market changes. Modularisation§ is widely used to increase the agility of automation systems, such that they may be more readily reconfigured¶. Also with globalisation into India and Asia semi-automatic machines (machines that interact with human operators) are more frequently used to reduce capital outlay and increase flexibility. There is an increasing need for tools and methodologies that support this in order to improve design robustness, reduce design time and gain a competitive edge in the market. The research presented in this thesis is built upon the work from COMPAG/COMPANION (COMponent- based Paradigm for AGile automation, and COmmon Model for PArtNers in automatION), and as part of the BDA (Business Driven Automation), SOCRADES (Service Oriented Cross-layer infrastructure for Distributed smart Embedded deviceS), and IMC-AESOP (ArchitecturE for Service- Oriented Process – monitoring and control) projects conducted at Loughborough University UK. This research details the design and implementation of a toolkit for building and simulating automation systems comprising components with behaviour described using Finite State Machines (FSM). The research focus is the development of the engineering toolkit that can support the automation system lifecycle from initial design through commissioning to maintenance and reconfiguration as well as the integration of a virtual human. This is achieved using a novel data structure that supports component definitions for control, simulation, maintenance and the novel integration of a virtual human into the automation system operation