The Production System Development ProcessSeptember 22, 2015

A process

• Process • repetitive network • activities • uses information and resources• transform ‘object in’ to ‘object out’, • customer satisfaction

• Method• prescribed approach• Guides user• e.g. implement a new system”

Problem

Analysis of situation

Conceptual modelling

Evaluation of concepts

Evaluation of concepts

Decision

Solution

Setting of objectives

Decision

Detailed design

Wu, 1994

Development as a process

• A process is as a road, starting with a need and ending in satisfaction

• The road (process) is used by different vehicles (projects)

A process goes through departments

PROCESS

PROCESS

PROCESS

Department Department Department

Output Input

Arguments for a process perspective on system development

• Overlook functional borders to solve problems• Improve ability to meet the customer in a comprehensive manner• Prerequisites for learning and development of knowledge

Benefits of a holistic approach

● System designers - no essential information is left out.

● Project managers – what exists in the organization and what needs to be taken care of.

● Documentation – information and higher commitment to proposed solution.

● Production system – verification on time, reduce risk of installation, problems and disturbances before SOP.

● Information – Reuse for future development. Learn from past speed up design.

Common activities in the design process

• Analysis

• Requirement specification

• Design or construction of

subsystems

• Integration of subsystems

into totality

• Evaluation and decision

Carin Rösiö JTH

Problem

Analysis of situation

Conceptual modelling

Evaluation of concepts

Evaluation of concepts

Decision

Solution

Sett ing of objectives

Decision

Detailed design

Chapter 5

Practical approaches to system design

Carin Rösiö JTH

Problem

Analysis of situation

Conceptual modelling

Evaluation of concepts

Evaluation of alternatives

Decision

Solution

Setting of objectives

Decision

Detailed design

Problem

Analysis of situation

Conceptual modelling

Evaluation of concepts

Evaluation of alternatives

Decision

Solution

Setting of objectives

Decision

Detailed design

Problem

Analysis of situation

Conceptual modelling

Evaluation of concepts

Evaluation of alternatives

Decision

Solution

Setting of objectives

Decision

Detailed design

A: Concept-generating approach B: Concept-driven approach C: Supplier-driven approach

Chapter 5

Production system development framework – a “mindset”

• Increased understanding

• Design is a double task:

• Planning of the design task

• The actual design task

• Also includes context and

the consequences

(performance)

Bellgran and Säfsten 2010

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and controlStructured

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Detailed design

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Start-upRealizationand planning

Contextual aspects

● Perspective and attitudes● Individuals, engagement, resource allocation to

production engineering and production development,short-term vs long-term perspective, focus on output, acomprehensive view, separating means and ends

● Company preconditions● Market requirements, production’s role, company culture,

management involvement

● Investment considerations● Reasons for investing, investment decisions

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Preparatory design

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DESIGN AND EVALUATEDESIGN AND EVALUATE

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Performance

● Measures aligned with strategic intentions and competitive priorities

● Performance measurement systems

Flexibility

Dependability

Cost

Speed

Quality

Requirements of the market Production system

performance

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Preparatory design

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Management and control of the project

● Allocation of resources to production● Daily operations vs long-term development,

production development vs product development

● Time perspective● Need varies, product life cycle vs production system

● Work team composition● Composition, internal/external personnel, project

management, information flow, communication

● Creativity and analytical ability● vs systematic, team composition

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Preparatory design

Detailed design

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Bellgran and Säfsten 2010

● Time limits puts pressure on schedule● Guarantee outcome● Facilitates coordination● Facilitates project management● Identification of areas for improvements● Long-term ability● Permit Control and Creativity ● …

Why a structured methodology?

Preparatory design

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Preparatorydesign

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Structured way of working

Preparatory design

Design specification

DESIGN AND EVALUATE

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Start-up Realisation and planning

PREPARATORY DESIGN

Background studyPhase A Phase B

Pre-study

Requirement specification

Plan for production system development

Preparatory design

● Background study – look backwards and inwards● Pre-study – look ahead/strategically/tactically

Backgroundstudy

Pre-study

•Analyze product and existing production system•Evaluate existing production system, own as well as others•Study existing documentation•Benchmark•Collect product data

•Analyze development and market potential •Identify interested parties demands, management’s targets/strategies, and interfaces towards surrounding environment•Identify internal/external production processes

Requirement specification

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Preparatorydesign

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Start-up

Start-up

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Market Complex 1 9 8 7 6 5 4 3 2 1 Stable

Customers Existing/new (50/50 %) Existing (100 %)

Competitors’ new technology High None

Competitors’ similar technology High None

Regulations Several/tough Few/easy

Markets Several Few

Production Complex Stable

Volume size (volume/years) High Average

Volume variations High Stable

Planning Short-term Long-term

Fluctuations (time intervals) Irregular None

Product Complex Stable

Generation Mix of existing and new New

Product variations High Low

New technologies Several None

New branches/applications Several None

Product range expansions Several None

Organization Complex Stable

Competence Hard to find Easy to find

Management involvement High Low

Growth of organization High Low

Production sites Several Single

Complex scenarioEstimating a

probable scenario Stable scenario

Design specification

● Design of conceptual production systems● Evaluation of conceptual production systems● Detailed design of chosen production system

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Phase CDevelop conceptual production systems

DETAILED DESIGN

Evaluate conceptual production systems

Phase D

Phase EDetailed design of chosen

production system

System solution

● Choose methods/tools and strategies

● Establish modules, sub-systems, operations, process

and layout, material supply, level of automation,

information, control and supervision, machinery and

equipment, work organization, work environment

● Handle complexity

● Iterate more solutions

● Communicate and find support for the solutions

Design of conceptual production systems

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Start-up

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● Choose method for evaluation

● Compare alternative solutions with regards to

requirements

● Calculate costs

● Summarize and communicate results from evaluation

● Make choice, communicate, and find support for

chosen solution

Evaluation of conceptual production system solutions C

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Detailed design of chosen system

● Proceed with chosen solution and formulate

detailed specification

● Design work place and work tasks

● Evaluate and find support for chosen solution

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● Build production system

● Plan start-up

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Realisation and planning

Planstart-up

Buildproduction

system

•Decide what will be bought/manufactured•Ask for tenders•Evaluate suppliers•Purchase equipment•Install•Verify

•Choose model for start-up•Prepare organization, appoint responsible•Plan training of personnel

Physical production system

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● Carry out production start-up● Follow plans from preceding phase

● Evaluate result● Evaluate final production system and development

process, feed-back results to process owner

Start-up of production system

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Production system design support

On optimal design process should tell:• What should be done and when• What techniques and tools will be needed at each stage• What information needs to be collected• What the output or result of each stage would be

(Love, 1996)

Important features of a process:• Simple to be widely used by engineers• Efficient with minimum trial-and-error effect• Versatile to be applicable in different situations• Prescriptive instead of descriptive to recommend the

soultions(Houshmand and Jamshidnezhad, 2006)