DECISION SUPPORT SYSTEMS FOR THE PLANNING OF MODULAR...

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Speaker: Markus Zajac, Fraunhofer IML

DECISION SUPPORT SYSTEMS FOR THE PLANNING OF MODULAR PLANTS IN PROCESS INDUSTRY

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Structure

1. Challenges for the process industry

2. Modular plants in process industry

3. Decision-making support in modular plant design

4. Introduction of the LEGOLAS project

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Structure





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Process industry faces enormous challenges

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Main drivers / accelerators for new production and logistics concepts

Market volatilities and demand oriented production

Customer individual logistics and demand of production for small batch sizes

Distributed production nearby the customer / feedstock

Short Time-to-Market

Increasing individualizationendlhausen-pharma.de/de/entwicklung.php

© Wrangler - Fotolia.com

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Challenges and drivers requires transformable production and logistics systems

Current production and logistics systems

Long time periods of planning and implementation

Insufficient adaptability causes oversizing and increased consumption of energy and resources

Storage and transmission systems are difficult to adapt to modificationsBASF

Modular production concept is a promising approach to meet this challenges and drivers.

Research association F3

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Structure





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Modular production concepts

Modularization: “Designing with standardized units, dimensions or interfaces, which can be easily assembled, maintained as well as flexibly arranged and operated”

Logistics modules are mobile, decentralized operated and controlled units that perform a specific task related to production logistics

• Packaging

• Storing

• Filling

• PickingResearch association ModuLOG

Research association F3

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Strengths and weaknesses of modularization

Improved flexibility and efficiency by reconfigurable multi-purpose production plants

Smaller capital expenditure by reuse of modules addressing short product cycles

Performance under ideal conditions, with market fluctuations modules are switched on or off (scaling)

Extra effort for the first implementation and maintenance of a modular engineering approach

Limited applicability to world scale plants (losses in economy of scale)

Picture: Bayer Media Pool & Invite GmbH


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Case: Manufacturing of radio-pharmaceutical products

Benefits of modular design

o Due to limited radioactive half-life, local production is

required (e.g. production in hospitals)

o Adjustment of production capacities according to

market demand

o Standard confection

Logistics challenges

o Handling of radioactive substances

o Fast and reliable distribution processes

o Special packaging and logistics procedures

o Really small handling units and production quantities

Subject

o Innovative oncological pharmaceutical product based

on radioactive substances with really short half-life

o Local fights of cancer cells (punch of radiation

directly to tumor cells that have invaded the bone)

o Radiation travels only a very short distance through

body tissue and very little radiation escapes from

treated patients

Picture: Google images

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Preliminary work in previous research projects

F³ (Fast, Flexible, Future) – Factory

▪ Production facilities as containers enables flexible relocating and supplementing of production processes

▪ Intensified processes reduce production costs and create opportunities in manufacturing new products

▪ Smaller batches are more profitable due to continuous production

▪ Accelerated product and process development

ModuLOG

▪ Automatic arrangement of modular container systems

▪ Development of a storage container that is compatible with a modular chemical production

▪ Conceptual development of other modules e.g. buffer, packaging, filling, cleaning and provision

Research association ModuLOG

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Research must focus on matching logistics units and processes as well as…

1. Adaptation of the handling units

o Standardization and modularization of the equipment for unloading, filling, packaging, storage and transportation activities

Flexible and consistent logistics units

Speed up the processes

Quickly react to changes

2. Adaptation of logistics processes

o Standard interfaces and autonomous control schemes for handling units

Centralized systems for the processes not feasible

Intelligence in parts and equipment requires for decentralization and self-organization

„Plug and Produce“ paradigm


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…enabling planning activities & staff to leverage benefits of modularization

3. Shortening and automation of the planning activities for setting up the logistics processes

o Powerful assistant systems needed to develop

Parts lists of needed handling units

Interconnections/control schemes of handling units

Cost estimations for investments and operations

4. Training and education of the plant labor for the installation of logistics units, control schemes and maintenance

o Professionally handle the equipment variety

Employees need to be trained

Elaboration of business cases for the organization of plant labor

Picture: Bayer News Channel

Picture: Bayer News Channel

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Structure





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Decision Making in Value Creation Systems

?

How to schedule the resources?

How to shift orders if there

is an exception?

Which technology is

the best?

What is the correct

dimension of the

warehouse?

How to design the

processes?

How to organize the fire fighting?

Which is the optimal order

sequence?

Design

Operation

Planning

Planning

Operation

DesignDesign

Design Planning Operation

Lifecycle of Logistics Systems

The task and object to be planned in all phases of the life cycle is always the same:

Organise logistic objects to be transformed in processes by resources of the logistics systems”

But methods change radically:

Design: Simulation and Excel

Planning ERP and Excel

Operations: Intuition

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What is really needed?

1. Business objectives of how the system should perform

2. Current Status of the system and assumed system load

3. Decision Scenarios that describe a concrete system and its logic of execution

4. Evaluation of theses Scenarios that takes the dynamics into account

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The Digital Twin as Simulation-based Decision Support System

Digital Twin stores the data (current and past status)

Decision Support Services generate the scenarios

Online-Simulationevaluates scenarios

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Structure





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Objectives of LEGOLAS research projectLEGO ≙ModuleLAS ≙ Logistical Assistance System ≙ Decision Support System

The current market conditions require adaptable modular production lines

Modular production concepts represent an innovation and, at the same time, a radical departure from existing design principles in the process industry

Goal of the project:

Development of a planning system based on Digital Twin to▪ Accelerate planning of modular production plants▪ Evaluate modular systems by means of indicators

An IT-supported planning system (DSS) is indispensable for the planning and assessment of modular production plants

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Work package - Operating concepts and business models

1. Concept for accelerated plant planning

2. Consideration of risk factors

3. Development of operating concepts

4. Development of business models

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Work package - Development of a planning system

1. Design of missing logistics modules (research gap)

2. Further development of a Digital Twin (module library)

3. Development of a planning system

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The project consortium

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Decision Support Systems for the planning of modular plants in process industry

THANK YOU FOR YOUR ATTENTION!

Contact:

Markus Zajac

E-Mail: [email protected]: +49 (0)231 9743-380

Fraunhofer-Institute for Material Flow and LogisticsDepartment Information Logistics and Decision Support SystemsJoseph-von-Fraunhofer Str. 2-444227 Dortmund, Germany

DECISION SUPPORT SYSTEMS FOR THE PLANNING OF MODULAR...

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