Lean Changeability – Evaluation and Design of Lean and Transformable Factories
In today-s turbulent environment, companies are faced with two principal challenges. On the one hand, it is necessary to produce ever more cost-effectively to remain competitive. On the other hand, factories need to be transformable in order to manage unpredictable changes in the corporate environment. To deal with these different challenges, companies use the philosophy of lean production in the first case, in the second case the philosophy of transformability. To a certain extent these two approaches follow different directions. This can cause conflicts when designing factories. Therefore, the Institute of Production Systems and Logistics (IFA) of the Leibniz University of Hanover has developed a procedure to allow companies to evaluate and design their factories with respect to the requirements of both philosophies.
Factory planning, lean production, transformability
Optimal Measures in Production Developing an Universal Decision Supporter for Evaluating Measures in a Production
Due to the recovering global economy, enterprises are
increasingly focusing on logistics. Investing in logistic measures for
a production generates a large potential for achieving a good starting
point within a competitive field. Unlike during the global economic
crisis, enterprises are now challenged with investing available capital
to maximize profits. In order to be able to create an informed and
quantifiably comprehensible basis for a decision, enterprises need an
adequate model for logistically and monetarily evaluating measures
in production. The Collaborate Research Centre 489 (SFB 489) at the
Institute for Production Systems (IFA) developed a Logistic
Information System which provides support in making decisions and
is designed specifically for the forging industry. The aim of a project
that has been applied for is to now transfer this process in order to
develop a universal approach to logistically and monetarily evaluate
measures in production.
Measures in Production, Logistic Operating Curves,
Transfer Functions, Production Logistics
Efficient Supplies to Assembly Areas from Storage Stages
Guaranteeing the availability of the required parts at
the scheduled time represents a key logistical challenge. This is
especially important when several parts are required together. This
article describes a tool that supports the positioning in the area of
conflict between low stock costs and a high service level for a
Systems Modeling, Manufacturing Systems,Simulation & Control, logistics and supply chain management
Dynamics In Production Processes
An increasingly dynamic and complex environment poses huge challenges to production enterprises, especially with regards to logistics. The Logistic Operating Curve Theory, developed at the Institute of Production Systems and Logistics (IFA) of the Leibniz University of Hanover, is a recognized approach to describing logistic interactions, nevertheless, it reaches its limits when it comes to the dynamic aspects. In order to facilitate a timely and optimal Logistic Positioning a method is developed for quickly and reliably identifying dynamic processing states.
Dynamics, Logistic Operating Curves, Production Logistics, Production Planning and Control
Learning Factory for Changeability
Amongst the consistently fluctuating conditions
prevailing today, changeability represents a strategic key factor for a
manufacturing company to achieve success on the international
markets. In order to cope with turbulences and the increasing level of
incalculability, not only the flexible design of production systems but
in particular the employee as enabler of change provide the focus
here. It is important to enable employees from manufacturing
companies to participate actively in change events and in change
decisions. To this end, the learning factory has been created, which is
intended to serve the development of change-promoting competences
and the sensitization of employees for the necessity of changes.
Changeability, human resources, learning factory.
Information Fusion as a Means of Forecasting Expenditures for Regenerating Complex Investment Goods
Planning capacities when regenerating complex investment goods involves particular challenges in that the planning is subject to a large degree of uncertainty regarding load information. Using information fusion – by applying Bayesian Networks – a method is being developed for forecasting the anticipated expenditures (human labor, tool and machinery utilization, time etc.) for regenerating a good. The generated forecasts then later serve as a tool for planning capacities and ensure a greater stability in the planning processes.
Bayesian networks, capacity planning, complex investment goods, damages library, forecasting, information fusion, regeneration.
Individual Configuration of Production Control to Suit Requirements
The logistical requirements placed on industrial manufacturing companies are steadily increasing. In order to meet those requirements, a consistent and efficient concept is necessary for production control. Set up properly, production control offers considerable potential with respect to achieving the logistical targets. As experience with the many production control methods already in existence and their compatibility is, however, often inadequate, this article describes a systematic approach to the configuration of production control based on the Lödding model. This model enables production control to be set up individually to suit a company and the requirements. It therefore permits today-s demands regarding logistical performance to be met.
Production, planning, control, configuration.
Enhanced Economic Evaluation – Approach for a Holistic Evaluation of Factory Planning Variants
The building of a factory can be a strategic investment
owing to its long service life. An evaluation that only focuses, for
example, on payments for the building, the technical equipment of
the factory, and the personnel for the enterprise is – considering the
complexity of the system factory – not sufficient for this long-term
view. The success of an investment is secured, among other things,
by the attainment of nonmonetary goals, too, like transformability.
Such aspects are not considered in traditional investment calculations
like the net present value method. This paper closes this gap with the
enhanced economic evaluation (EWR) for factory planning. The
procedure and the first results of an application in a project are
economic efficiency, holistic evaluation, factory
Dynamically Monitoring Production Methods for Identifying Structural Changes relevant to Logistics
Due to the growing dynamic and complexity within
the market environment production enterprises in particular are faced
with new logistic challenges. Moreover, it is here in this dynamic
environment that the Logistic Operating Curve Theory also reaches
its limits as a method for describing the correlations between the
logistic objectives. In order to convert this theory into a method for
dynamically monitoring productions this paper will introduce
methods for reliably and quickly identifying structural changes
relevant to logistics.
Dynamics, Logistic Operating Curves, Production
Logistics, Production Planning and Control
Identifying Interactions in a Feeding System
In production processes, assembly conceals a considerable potential for increased efficiency in terms of lowering production costs. Due to the individualisation of customer requirements, product variants have increased in recent years. Simultaneously, the portion of automated production systems has increased. A challenge is to adapt the flexibility and adaptability of automated systems to these changes. The Institute for Production Systems and Logistics developed an aerodynamic orientation system for feeding technology. When changing to other components, only four parameters must be adjusted. The expenditure of time for setting parameters is high. An objective therefore is developing an optimisation algorithm for automatic parameter configuration. Know how regarding the interaction of the four parameters and their effect on the sizes to be optimised is required in order to be able to develop a more efficient algorithm. This article introduces an analysis of the interactions between parameters and their influence on the quality of feeding.
Aerodynamic feeding system, design of experiments, interactions between parameters.
Assessing and Improving Ramp-Up Capability
In times when product life cycles are decreasing, while market demands are increasing, manufacturing enterprises are confronted with the challenge of more frequent and more complex ramp-ups. Thus it becomes obvious that ramp-up management is going to be a topic enterprises have to focus on in the future. Since each ramp-up is unique concerning the product, the process, the technology, the circumstances and the coaction of these four factors, the knowledge of the ramp-up situation and the current ramp-up capability of the enterprise are fundamental requirements for the subsequent improvement of the ramp-up capability of the production system.
In this article a methodology is going to be presented which can be used to define typical production ramp-up situations, to identify the current ramp-up capability of a production system and to improve it with respect to a specific situation. Additionally there will be a description of the functionality of a software-tool developed based on this methodology.
Assessment methodology, ramp-up, ramp-up capability, software-tool.
Cost Sensitive Analysis of Production Logistics Measures A Decision Making Support System for Evaluating Measures in the Production
Due to the volatile global economy, enterprises are increasingly focusing on logistics. By investing in suitable measures a company can increase their logistic performance and assert themselves over the competition. However, enterprises are also faced with the challenge of investing available capital for maximum profits. In order to be able to create an informed and quantifiably comprehensible basis for a decision, enterprises need a suitable model for logistically and monetarily evaluating measures in production. Previously, within the frame of Collaborate Research Centre 489 (SFB 489) at the Institute for Production Systems and Logistics, (IFA) a Logistic Information System was developed specifically for providing enterprises in the forging industry with support when making decisions. Based on this research, a new initiative referred to as ‘Transfer Project T7’, aims to develop a universal approach for logistically and monetarily evaluating production measures. This paper focuses on the structural measure echelon storage and their impact on the entire production system.
Logistic Operating Curves, Transfer Functions, Production Logistics, Storages Echelon.
Evaluating the Logistic Performance Capability of Regeneration Processes
For years now, it has been recognized that logistic performance capability contributes enormously to a production enterprise’s competitiveness and as such is a critical control lever. In doing so, the orientation on customer wishes (e.g. delivery dates) represents a key parameter not only in the value-adding production but also in product regeneration. Since production and regeneration processes have different characteristics, production planning and control measures cannot be directly transferred to regeneration processes. As part of a special research project, the Institute of Production Systems and Logistics Hannover is focused on increasing the logistic performance capability of regeneration processes for complex capital goods. The aim is to ensure logistic targets are met by implementing a model specifically designed to align the capacities and load in regeneration processes.
Capacity planning, complex capital goods, logistic performance, regeneration process.
Multi-Objective Optimization of an Aerodynamic Feeding System Using Genetic Algorithm
Considering the challenges of short product life cycles
and growing variant diversity, cost minimization and manufacturing
flexibility increasingly gain importance to maintain a competitive
edge in today’s global and dynamic markets. In this context, an
aerodynamic part feeding system for high-speed industrial assembly
applications has been developed at the Institute of Production
Systems and Logistics (IFA), Leibniz Universitaet Hannover. The
aerodynamic part feeding system outperforms conventional systems
with respect to its process safety, reliability, and operating speed. In
this paper, a multi-objective optimisation of the aerodynamic feeding
system regarding the orientation rate, the feeding velocity, and the
required nozzle pressure is presented.
Aerodynamic feeding system, genetic algorithm,
Batch-Oriented Setting Time Optimisation in an Aerodynamic Feeding System
The change of conditions for production companies in
high-wage countries is characterized by the globalization of
competition and the transition of a supplier´s to a buyer´s market. The
companies need to face the challenges of reacting flexibly to these
changes. Due to the significant and increasing degree of automation,
assembly has become the most expensive production process.
Regarding the reduction of production cost, assembly consequently
offers a considerable rationalizing potential. Therefore, an
aerodynamic feeding system has been developed at the Institute of
Production Systems and Logistics (IFA), Leibniz Universitaet
Hannover. This system has been enabled to adjust itself by using a
genetic algorithm. The longer this genetic algorithm is executed the
better is the feeding quality. In this paper, the relation between the
system´s setting time and the feeding quality is observed and a
function which enables the user to achieve the minimum of the total
feeding time is presented.
Aerodynamic feeding system, batch size,
optimisation, setting time.
Optimization Model for Identification of Assembly Alternatives of Large-Scale, Make-to-Order Products
Assembling large-scale products, such as airplanes, locomotives, or wind turbines, involves frequent process interruptions induced by e.g. delayed material deliveries or missing availability of resources. This leads to a negative impact on the logistical performance of a producer of xxl-products. In industrial practice, in case of interruptions, the identification, evaluation and eventually the selection of an alternative order of assembly activities (‘assembly alternative’) leads to an enormous challenge, especially if an optimized logistical decision should be reached. Therefore, in this paper, an innovative, optimization model for the identification of assembly alternatives that addresses the given problem is presented. It describes make-to-order, large-scale product assembly processes as a resource constrained project scheduling (RCPS) problem which follows given restrictions in practice. For the evaluation of the assembly alternative, a cost-based definition of the logistical objectives (delivery reliability, inventory, make-span and workload) is presented.
Assembly scheduling, large-scale products, make-to-order, rescheduling, optimization.