Interdependencies between energy productivity and target figures of lean production systems

Part of: Seliger, Günther (Ed.): Innovative solutions : proceedings / 11th Global Conference on Sustainable Manufacturing, Berlin, Germany, 23rd - 25th September, 2013. - Berlin: Universitätsverlag der TU Berlin, 2013. - ISBN 978-3-7983-2609-5 (online). - http://nbn-resolving.de/urn:nbn:de:kobv:83-opus4-40276. - pp. 137–142.Energy productivity will be a significant competitive advantage for manufacturing companies in future. Therefore, a methodical approach is necessary to identify potential in manufacturing and reduce energy waste. In order to develop this approach, it is obligatory to consider interdependencies to established production systems. Starting with Toyota, car manufacturers were pioneers for the implementation of Lean Production Systems (LPS). Their production processes are measured by LPS target figures like quality or through-put time. Efforts to raise energy productivity can cause impacts on existing production processes and therefore result in interdependencies with LPS target figures. The methodology presented in this paper helps to increase energy productivity under consideration of these interdependencies. The so called House of Energy Productivity is introduced as one important part of the methodology

CFD-Simulations in the Early Product Development

AbstractA growing range of products shifts the product development in focus. Especially the early design phase defines the costs and quality. Thus, to ensure the quality of the products, different concepts are designed and evaluated. A tool for the evaluation of the different designs is simulation due to being fast and cost efficient. But simulation in the early phase still remains a problem. This results of the basic and fast changing concepts, which take too much effort to be converted into a simulation model. To get around these circumstances, we propose a method for an online modelling in the design process. Instead of defining the simulation model at once, the method modificates the simulation model during simulation run time. Furthermore, the functionality is shown in a CFD simulation using the meshless Smoothing Hydrodynamics method. Using the GPU to achieve real-time simulation, the method allows a WYSIWYG design-simulation development helping to raise the quality of products

Approaches for the Simulation of Deformable Objects in Manufacturing Systems

The validation of control software using methods of Virtual Commissioning (VC), with its origin in the field of machine tools, gains more and more importance in other application areas like process engineering or material-flow-intensive production systems. Especially because of the increasing complexity of technical systems the validation of the control software quality is a major challenge in production technology. To reduce the efforts of modeling and to increase the value of simulation results, a so-called physically model is integrated in the VC. Currently the physically based Virtual Commissioning is restricted to rigid body simulation objects. In this publication new methods for the simulation of deformable objects are shown and validated in an industrial context. Therefore the hybridization of existing simulation methods from computer science using so called physic engines is introduced as a method that simplifies the description of complex simulation objects by adapting well known simulation models. The new approach is comparable to a mixture of a multi body simulation and a real-time finite element simulation

Modular Configuration of an RFID-based Hybrid Control Architecture for a Situational Shop Floor Control

Nowadays, producing companies act in a turbulent environment, which is caused by the globalization of the economy and the continuous shift from seller markets to buyer markets. One central aspect is the demand for customized products at short delivery times and reasonable costs. In this context, shop floor control becomes more and more important and therefore, the complexity of its purposes increases. However, current shop floor information, which is indispensable for a targeted execution of these purposes, is often not available. The RFID (Radio Frequency Identification) technology enables an adequate and situational shop floor control. Since the integration and capabilities of RFID depends on specific framework conditions (e.g. forms of organization), an approach for a modular configuration of an RFID-based hybrid control architecture, that separates control efforts into centralized and decentralized control elements, is motivated. Finally, this approach could be implemented to a use case of a German automotive seat supplier

A methodology for simulation production systems considering the degree of autonomy

The increasing number of product varieties and declining product life cycles combined with individualised customer behaviour demand flexible and efficient production systems. A proper solution approach can be the use of intelligent technologies, capable of autonomous processing in order to react rapidly to changing requirements. However, production planners need a profound planning approach for the implementation of such technologies in production systems due to their cost intense investments. Therefore, simulation studies are suitable means for the analysis of a proper degree of autonomy in production systems. An appropriate methodology for the simulation of such systems is presented in this paper. The methodology is aligned with common guidelines on simulation studies and focuses on system analysis, formalisation and simulation. It is based on consistent methods – fact sheets and Value Stream Design for system analysis, Unified Modelling Language (UML) diagrams for formalisation and agent-based simulation. A central contribution to current research is the modular modelling of intelligence skills in production resources and parts in a simulation environment. Consequently, the developed methodology provides a basis for the implementation of simulation experiments in order to facilitate the evaluation of the economically efficient use of intelligent objects in production systems

Incentive System Framework for Information Sharing in Value-Adding Networks

To meet current market requirements and improve their competitive position, companies cooperate with their partners in value-adding networks. To exploit potential performance improvements, it is essential for companies to increasingly share Production Planning and Control-related data. Financial and non-financial incentives are beneficial to foster the inter-company exchange of such data. This paper proposes an approach for designing an application-specific incentive system framework, forcing information sharing in value-adding networks. The framework is based on a requirements analysis towards both value-adding networks and Production Planning and Control. The outcome of the approach is the possibility of deriving concrete incentive systems. The approach developed was applied and verified in a use case

Waste Reduction by Product-Quality Based Scheduling in Food Processing

AbstractRelated to resource efficiency waste reduction is the crucial point in the processing of food. As shown in different Food Waste Studies the amount of waste in food processing is enormous. Up to 400.000 metric tons of edible food is disposed every year caused by wrong treatment, handling and processing. Processing is the major point to deal with. In the case of manual processing in a cantina kitchen waste can be classified into waste associated with overproduction, product damages or technical interruptions. To reduce the amount of loss by using technical solutions it is possible to reduce up to 60 % of loss during the processing. Related to the product itself the automation and especially the scheduling of the processes in a commercial kitchen is more complex than the scheduling of standard products e.g. in the automotive sector. This article shows a solution to extend the criteria of production planning within an automated food processing environment. The paper introduces a product model that prescribes the progress of product quality while processing

Engineered Hours Per Product for Simultaneous Engineering

AbstractModern Cooperative Engineering approaches suggest a transparent tracking of production costs during development stages. The traditional concept of Engineered Hours per Product, originally developed for the automotive industry, focusses on specific production and assembly times. Necessary but auxiliary tasks are ignored since their reduction is within the domain of production departments. Thereby this approach promotes the decrease of production time but does not give an adequate measure to compare design alternatives. This paper presents a complementary approach based on the assumption that the production system has reached a stable status and remains relatively constant for new variants. Based on existing products core time drivers based on features are successively identified until an adequate approximation of the time for the current product is achieved. Those time drivers thereby include the total time to perform the task, including auxiliary task and can be used during the development stage. The paper concludes with an industrial case study to illustrate the benefits

Tactical Production Planning for Customer Individual Products in Changeable Production Networks

The requirements of future production are characterized by increasing demand volatility as well as very short delivery times and high timeliness in the order-based production environment. Furthermore, the trend to customer individual products leads to additional production planning challenges. Therefore, to react fast to these market trends, changeable production networks is a key to success. This technical contribution describes a method for tactical production planning for customer individual products in changeable production networks. The design of the method contains three main process modules (1) order-capability-comparison, (2) capacity planning, and (3) order-specific network structure. Underlying the former described modules, a data model is necessary and introduced. Furthermore, the simulation of the applied system on a prototypical implementation at BSH Hausgeräte GmbH, the largest home appliances manufacturer in Europe, is shown and explained. Finally, limitations are discussed and an outlook into future work for the research field in production planning of production networks is given