Framework For Life Cycle Oriented Production System Design · summarized as Lean Production Systems...
Transcript of Framework For Life Cycle Oriented Production System Design · summarized as Lean Production Systems...
1
1Technical University of Braunschweig | Institute of Machine Tools and Production Technology
Framework For Life Cycle Oriented Production System Design
Christoph HerrmannLars BergmannAndré Zein
40th CIRP International Seminar on Manufacturing Systems
May 30th – June 1st, 2007, Liverpool, UK
Liverpool, 31th May 2007
2Technical University of Braunschweig | Institute of Machine Tools and Production Technology
> Introduction
> Challenges and current Situation of Production System Design
> Research Objectives
> Framework Approach for Production System Design
> Linking Systems Thinking and Life Cycle Thinking for Production System Design
> Frame of Reference for Production System Design
> Software Implementation of the Framework Approach
> Conceptual Structure and Information Flow of the Framework
> Overview of current State of Development
> Conclusion
OUTLINE
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3Technical University of Braunschweig | Institute of Machine Tools and Production Technology
> Introduction
> Challenges and current Situation of Production System Design
> Research Objectives
> Framework Approach for Production System Design
> Linking Systems Thinking and Life Cycle Thinking for Production System Design
> Frame of Reference for Production System Design
> Software Implementation of the Framework Approach
> Conceptual Structure and Information Flow of the Framework
> Overview of current State of Development
> Conclusion
OUTLINE
4Technical University of Braunschweig | Institute of Machine Tools and Production Technology
Production System improvement is driven by dynamic impact factors
Increasing demand for efficient and flexible production systems
Current approach of European production companies: Toyota Production System
INTRODUCTION
New (European andNational) Legislation
Rapidly ChangingTechnologies
Shorter Product Lifecycle
Increasing Labor Costs
Fluctuant ProductionVolumes and Revenues
Increasing Costs andMarket Competition Production System
Basic Requirement:Continuously Adaptation
Processes, Resources, Principles, Methods
IMPACT FACTORS FOR PRODUCTION SYSTEMS
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5Technical University of Braunschweig | Institute of Machine Tools and Production Technology
THE TOYOTA PRODUCTION SYSTEM
> General framework and philosophyto design and organize the manufacturing system
> Objective: Provide best quality, lowest cost, shortest lead time through the elimination of waste
> As the main goal of the TPS is to eliminate waste, TPS is generally known as lean production
> Toyota was capable of significantly reducing cost and inventory using the TPS, enabling it become one of the ten largest companies in the world
> TPS is continuously improvedthrough iterations of standardized work and kaizen
INTRODUCTION
TPSHighest Quality, Lowest Cost, Shortest Lead Time, Empowered Employees, best Safety, High Morale
Continuous FlowTakt TimePull SystemQuick Changeover
Just-in-Time Jidoka
Built-in QualityAndonError ProofingSeparation ofman & machine
Heijunka Stable and Standardized Processes Kaizen
Toyota Way Philosophy
People & Teamwork
Waste Reduction
Continuous Improvement
Figure 1: TPS House, adapted from Ohno 1998, Liker 2004
6Technical University of Braunschweig | Institute of Machine Tools and Production Technology
Subsystems
Principles
Methods /Tools
Generic Structure of Lean Production Systems
Quality WorkStructures
• Six Sigma• TQM• Stable processes• …
• DMAIC • FMEA• SPC• 5 Why• …
• Job rotation• Workload Analysis• Safety Analysis• Interview / Survey• …
• Teamwork• Ergonomics• Safety…
…
…
…
• Levelling• Pull System• One Piece Flow• …
Just in Time
• FiFo• SMED• Kanban• …
Kaizen
• Standardization• Muda-Elimination• Suggestion System• …
• Kaizen Workshop• PDCA• Standards• 5S• …
Subsystems
Principles
Methods /Tools
Generic Structure of Lean Production Systems
Quality WorkStructures
• Six Sigma• TQM• Stable processes• …
• DMAIC • FMEA• SPC• 5 Why• …
• Job rotation• Workload Analysis• Safety Analysis• Interview / Survey• …
• Teamwork• Ergonomics• Safety…
…
…
…
• Levelling• Pull System• One Piece Flow• …
Just in Time
• FiFo• SMED• Kanban• …
Kaizen
• Standardization• Muda-Elimination• Suggestion System• …
• Kaizen Workshop• PDCA• Standards• 5S• …
LEAN PRODUCTION SYSTEM IMPLEMENTATION IN EUROPE
> Due to the success of the TPS and faced with the rapidly developing changes in global markets the TPS framework and various of its inherent methods have been adapted by many European production enterprises (large-scale but also small and medium sized companies)
> As these ‘TPS adaptations’ show significant accordance, they can be summarized as Lean Production Systems (LPS)
> Only few European companies have achieved “lean” results, e.g. in terms of productivity and continuous improvement processes, like Toyota
Generic structure of Lean Production Systems
Restructuring
Euro
pe
Japan
INTRODUCTION
Success ?Adaptation
TPSHighest Quality, Lowest Cost, Shortest Lead Time, Empowered Employees, best Safety, High Morale
Continuous FlowTakt TimePull SystemQuick Changeover
Just-in-Time Jidoka
Built-in QualityAndonError ProofingSeparation ofman & machine
Heijunka Stable and Standardized Processes Kaizen
Toyota Way Philosophy
People & Teamwork
Waste Reduction
Continuous Improvement
Figure 1: TPS House, adapted from Ohno 1998, Liker 2004
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7Technical University of Braunschweig | Institute of Machine Tools and Production Technology
INTRODUCTION
PRODUCTION SYSTEM REQUIREMENTS CHANGE OVER THE PRODUCT LIFE CYCLE
> The Production System Design has to cope with different Products (P), strategic Objectives (SO), and Change Drivers (CD) over time
P1 Ramp up EOPMass Production
P2 Ramp upSOP
P3 SOP
Prod
ucts
(P)
Stra
tegi
c O
bjec
tives
(SO
)C
hang
e D
river
s (C
D)
SO1SO2
CD1
A
B
0,3
0,7
A
B
0,3
0,7
A
B
0,3
0,7
A
B
0,3
0,7
t1t0 timet2
8Technical University of Braunschweig | Institute of Machine Tools and Production Technology
INTRODUCTION
PRODUCTION SYSTEM REQUIREMENTS CHANGE OVER THE PRODUCT LIFE CYCLE
> The Production System Design has to cope with different Products (P), strategic Objectives (SO), and Change Drivers (CD) over time
> Different requirements over the Production System Life Cycle lead to changing Production System Capabilities (e.g. volume flexibility, dependability)
> Production System capabilities result from fulfilling certain Functional Requirements (FR) within the Production System
P1 Ramp up EOPMass Production
P2 Ramp upSOP
P3 SOP
Prod
uctio
n Sy
stem
Cap
abili
ties
Prod
ucts
(P)
Stra
tegi
c O
bjec
tives
(SO
)C
hang
e D
river
s (C
D)
SO1SO2
CD1
A
B
0,3
0,7
A
B
0,3
0,7
A
B
0,3
0,7
A
B
0,3
0,7
∆Capability
t1t0 timet2
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9Technical University of Braunschweig | Institute of Machine Tools and Production Technology
INTRODUCTION
PRODUCTION SYSTEM REQUIREMENTS CHANGE OVER THE PRODUCT LIFE CYCLE
> The Production System Design has to cope with different Products (P), strategic Objectives (SO), and Change Drivers (CD) over time
> Different requirements over the Production System Life Cycle lead to changing Production System Capabilities (e.g. volume flexibility, dependability)
> Production System capabilities result from fulfilling certain Functional Requirements (FR) within the Production System
> Design Parameters (DP) that allow to fulfill Functional Requirements have their own temporality and need efforts and time to take effect on the FR fulfillment
> The number of different Design Parameters and dynamic changing requirements impede the identification of appropriate Design Parameters
P1 Ramp up EOPMass Production
P2 Ramp upSOP
P3 SOP
Prod
uctio
n Sy
stem
Cap
abili
ties
Prod
ucts
(P)
Stra
tegi
c O
bjec
tives
(SO
)C
hang
e D
river
s (C
D)
SO1SO2
CD1
A
B
0,3
0,7
A
B
0,3
0,7
A
B
0,3
0,7
A
B
0,3
0,7
∆Capability
t1t0 timet2FR
Ful
fillm
ent
DP
Effo
rts FR Fulfillment Level
DP Effort: e.g.: Operator Training
10Technical University of Braunschweig | Institute of Machine Tools and Production Technology
INTRODUCTION
PRODUCTION SYSTEM IMPROVEMENT DYNAMICS
> Improvement Activities for Production System Design generally cause dynamic interactions
> Unknown dynamics often impede Production System Improvement processes
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11Technical University of Braunschweig | Institute of Machine Tools and Production Technology
0,5
1
1,5
2
2,5
3
10 20 30 40 50 60 70 80 90 100
8
1011 12
9
1613
14
1715
201918
211
45 6
7
32
Degree of Realization (%)
Impo
rtanc
e of
Des
ign
Para
met
er
Critical Design ParameterBalanced
Design Parameter
Overvalued Design Parameter
58,252,20Total Quality Management (TQM)2157,252,06Application of PPS software2053,752,01Employee self-organization1949,251,90Development of company network1849,001,63Team work1746,501,56Just in time production1641,251,75Application of ERP software1531,251,33Cooperation with university partner1430,001,45Total Productive Maintenance (TPM)1326,001,23Implementation of KANBAN1224,001,25Application of SCM software1123,251,31Application of PDM software1015,501,00Application of Six Sigma projects910,750,82Business Process Integration (EAI)862,002,37Integration and information of employee758,502,42Employee development and training655,252,34Extension of product portfolio554,002,30Sales promotion454,752,18Strategic planning and controlling354,252,14Development of company strategy252,252,11Cont. Improvement Process, Kaizen1
Realiz.(Mean)0-100
Import.(Mean)
0-3
Design Parameter(Principle, Method, Tool, etc.)Nr.
IMPORTANCE AND REALIZATION OF PRODUCTION SYSTEM DESIGN PARAMETER (own Survey, German SME, n=1955)
Survey on the Importance and Degree of Realization of Production System Design Parameters (Methods, Tools, etc.)
CURRENT SITUATION OF PRODUCTION SYSTEM IMPROVEMENT
> The establishment of a continuous improvement process and the strategic alignment of improvement activities represent some of the main problems today in German production SME
12Technical University of Braunschweig | Institute of Machine Tools and Production Technology
LEAN PRODUCTION SYSTEM IMPLEMENTATION
RESEARCH OBJECTIVES
> To support strategic and life cycle oriented Production System Design, it is necessary to support the following functions:
> The integration of strategic and product life cycle requirements into a structured planning process for production system design.
> The derivation of adequate Design Parameters (e.g. Methods, Tools, Principles, etc.) based on best-practice knowledge to support improvement efforts as decision support.
> The consideration of complex interdependencies to prevent unforeseen interactions and negative interrelations.
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13Technical University of Braunschweig | Institute of Machine Tools and Production Technology
> Introduction
> Challenges and current Situation of Production System Design
> Research Objectives
> Framework Approach for Production System Design
> Linking Systems Thinking and Life Cycle Thinking for Production System Design
> Frame of Reference for Production System Design
> Software Implementation of the Framework Approach
> Conceptual Structure and Information Flow of the Framework
> Overview of current State of Development
> Conclusion
OUTLINE
14Technical University of Braunschweig | Institute of Machine Tools and Production Technology
SYSTEMS THINKING – THE SYSTEMIC PLANNING PROCESS
THE SYSTEMIC PLANNING PROCESS
> The general systemic planning process provides a starting point for production system design
> The five steps of the planning process guide the planning team and supports the team to gain comprehensive understanding of the current situation and possible design solutions:
1. Identification of Chances, Risks and Capability Requirements
2. Understanding of dynamics, interrelations and conflicts of current and future situation, processes, methods, tools, etc.
3. Development of means and controls for viable production system design
4. Assessment of effects of possible design solutions and required optimization efforts
5. Realization and anchoring design solutionsProduction System
Understanding of Dynamics, Interrelations, and Conflicts of Situation
Development of Means and Controls for Viable Production Syst. Design
Assessment of possible Design Solutions and Optimization Efforts
Realization and Anchoring Design
Solutions
Identification of Chances, Risks and Capability
Requirements
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15Technical University of Braunschweig | Institute of Machine Tools and Production Technology
SYSTEMS THINKING – THE SYSTEMIC PLANNING PROCESS
SYSTEMIC PLANNING PROCESS FOR PRODUCTION SYSTEM DESIGN
> The planning and realization process has to consider manifold input information, such as corporate strategy, legal requirements, change driver, new technologies, and capability gaps
Production System
Understanding of Dynamics, Interrelations, and Conflicts of Situation
Development of Means and Controls for Viable Production Syst. Design
Assessment of possible Design Solutions and Optimization Efforts
Realization and Anchoring Design
Solutions
Identification of Chances, Risks and Capability
RequirementsCorporate Strategy
Legal requirements
New Technolog.
Change Driver
Capability Gaps
Prod
uctio
n S
yste
m D
esig
nG
uide
lines
Req
uire
men
t ful
film
ent
16Technical University of Braunschweig | Institute of Machine Tools and Production Technology
LINKING LIFE CYCLE THINKING AND SYSTEMS THINKING
LINKING THE SYSTEMIC PLANNING PROCESS WITH THE PRODUCT LIFE CYCLE
> The planning and realization process has to consider manifold input information, such as corporate strategy, legal requirements, change driver, new technologies, and capability gaps
Production System
Understanding of Dynamics, Interrelations, and Conflicts of Situation
Development of Means and Controls for Viable Production Syst. Design
Assessment of possible Design Solutions and Optimization Efforts
Realization and Anchoring Design
Solutions
Recycling & Disposal
Operations & Service
Industrial Engineering
DesignProcess
Identification of Chances, Risks and Capability
Requirements
Production
Corporate Strategy
Legal requirements
New Technolog.
Change Driver
Capability Gaps
Prod
uctio
n S
yste
m D
esig
nG
uide
lines
Req
uire
men
t ful
film
ent
Product Life Cycle
Information feedback loops
Information feedback loops
> The Product Life Cycle oriented Production System Design requires the proactively collection of requirements and other dependencies from all product life cycle phases
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17Technical University of Braunschweig | Institute of Machine Tools and Production Technology
FRAME OF REFRENCE FOR PRODUCTION SYSTEM DESIGN
Production System
Understanding of Dynamics, Interrelations, and Conflicts of Situation
Development of Means and Controls for Viable Production Syst. Design
Assessment of possible Design Solutions and Optimization Efforts
Realization and Anchoring Design
Solutions
Recycling & Disposal
Operations & Service
Industrial Engineering
DesignProcess
Identification of Chances, Risks and Capability
Requirements
Production
Information feedback loops
Corporate Strategy
Legal requirements
New Technolog.
Change Driver
Capability Gaps
Information feedback loops
Prod
uctio
n S
yste
m D
esig
nG
uide
lines
Req
uire
men
t ful
film
ent
Product Life Cycle
> The Product Life Cycle oriented Production System Design requires the proactively collection of requirements and other dependencies from all product life cycle phases
> Feedback information of current Production System Design of all life cycle phases is a prerequisite for long-term production system design optimization
LINKING THE SYSTEMIC PLANNING PROCESS WITH THE PRODUCT LIFE CYCLE
> The planning and realization process has to consider manifold input information, such as corporate strategy, legal requirements, change driver, new technologies, and capability gaps
18Technical University of Braunschweig | Institute of Machine Tools and Production Technology
FRAME OF REFERENCE FOR PRODUCTION SYSTEM DESIGN
AXIOMATIC DESIGN BASED DECOMPOSITION OF FUNCTIONAL REQUIREMENTS OF THE PRODUCTION SYSTEM
> To comprehensively describe and support the planning process, common understanding of complex production systems is necessary.
> The Manufacturing System Design Decomposition (MSDD) Approach by Cochran et al. (MIT, 1990) allows to separate objectives from the means of achievement of production system design.
Production System
Functional Design Description
FRDP
FRDP
FRDP
QualityCont. Improvement
Problem Solving
DelayReduction
Predictable Output
Costs &Investment
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19Technical University of Braunschweig | Institute of Machine Tools and Production Technology
FRAME OF REFERENCE FOR PRODUCTION SYSTEM DESIGN
AXIOMATIC DESIGN BASED DECOMPOSITION OF FUNCTIONAL REQUIREMENTS OF THE PRODUCTION SYSTEM
> To comprehensively describe and support the planning process, common understanding of complex production systems is necessary.
> The Manufacturing System Design Decomposition (MSDD) Approach by Cochran et al. (MIT, 1990) allows to separate objectives from the means of achievement of production system design.
> The central idea of axiomatic design is to distinguishing between what (objectives) is to be achieved and how (means) it will be achieved.
> In axiomatic design terminology, the objectives of the design are expressed as Functional Requirements (FRs) and the solutions are expressed as Design Parameters (DPs).
Production System
Functional Design Description
FRDP
FRDP
FRDP
QualityCont. Improvement
Problem Solving
DelayReduction
Predictable Output
Costs &Investment
Service equipment regularly
FR-P132
Regular preventive maintenance
program (TPM)
DP-P132
What is to be achieved?
How will it be achieved?Principles, Methods, Tools, …
20Technical University of Braunschweig | Institute of Machine Tools and Production Technology
FRAME OF REFERENCE FOR PRODUCTION SYSTEM DESIGN
ADDING INFORMATION TO FUNCTIONAL REQUIREMENTS AND DESIGN PARAMETERS
> To support the systemic planning process, the defined Functional Requirements and Design Parameters allow to add information for planning andevaluation purpose.
Service equipment
regularly
FR-P132
Regular preventive
maintenance program (TPM)
DP-P132
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21Technical University of Braunschweig | Institute of Machine Tools and Production Technology
FRAME OF REFERENCE FOR PRODUCTION SYSTEM DESIGN
ADDING INFORMATION TO FUNCTIONAL REQUIREMENTS AND DESIGN PARAMETERS
> To support the systemic planning process, the defined Functional Requirements and Design Parameters allow to add information for planning and evaluation purpose.
> FR-related information can be used to describe the current state and to describe interrelationsthat affect or are affected by FRachievement.
Cost
FR Contribution to Strategic Dimension
QualityDelivery DependabilityDelivery Throughput timeProduct Mix FlexibilityVolume Flexibility upVolume Flexibility downInnovativeness
++
oo
+
1
FRLevel
2
3
4
5
6
xService
equipment regularly
FR-P132
Regular preventive
maintenance program (TPM)
DP-P132
What is to be
achieved?
Which capability (strategic)
Dimension benefit from
FR achievement ?
Which Life Cycle Phase has
interrelations to FR achievement ?
Design Process
FR Life Cycle Phase Consideration / Impact
Industrial EngineeringProductionOperationServiceRecyclingDisposal
++
oo
C
+
oo
I
What is the current level of achieve-ment?
DB
22Technical University of Braunschweig | Institute of Machine Tools and Production Technology
FRAME OF REFERENCE FOR PRODUCTION SYSTEM DESIGN
ADDING INFORMATION TO FUNCTIONAL REQUIREMENTS AND DESIGN PARAMETERS
> To support the systemic planning process, the defined Functional Requirements and Design Parameters allow to add information for planning and evaluation purpose.
> FR-related information can be used to describe the current state and to describe interrelationsthat affect or are affected by FRachievement.
> DP-related information can be used to describe detailed information on DP application as well as the expected efforts and benefits of over time.
Cost
FR Contribution to Strategic Dimension
QualityDelivery DependabilityDelivery Throughput timeProduct Mix FlexibilityVolume Flexibility upVolume Flexibility downInnovativeness
++
oo
+
1
FRLevel
2
3
4
5
6
x
Training
DP Effort / Benefit
InvestmentApplicationBenefit / ContributionRequired employeesPsychological effectEstimated time for ROI
o-+o2o
1yrFR Level
Benefit
Time
Investment
Transfer
Application
Training
Anchoring
Time depended behavior of DP
Service equipment
regularly
FR-P132
Regular preventive
maintenance program (TPM)
DP-P132
How will it be achieved?
Design Process
FR Life Cycle Phase Consideration / Impact
Industrial EngineeringProductionOperationServiceRecyclingDisposal
++
oo
C
+
oo
I
How much time and resource will the Design Parameter cost?
How looks the estimated effort/
benefit ratio?
DB
DB
What is to be
achieved?
Which capability (strategic)
Dimension benefit from
FR achievement ?
Which Life Cycle Phase has
interrelations to FR achievement ?
What is the current level of achieve-ment?
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23Technical University of Braunschweig | Institute of Machine Tools and Production Technology
FRAME OF REFERENCE FOR PRODUCTION SYSTEM DESIGN
EXAMPLE FOR FUNCTIONAL STRUCTURE OF THE FRAMEWORK
> FR-DP-related Information can be used for assessment, evaluation, and analysis purpose.
Cost100
1
10
21
1
221
1,000,830,580,50
Level 3Level 2Level 1
Level 4
x
FR -
Q13
FR -
Q12
FR -
Q11
x
x
x x x
Level 5
Critical Area
Overfulfilled Area Competent Area
Neutral Area
Definition andPrioritization of
Strategic Objectives
Assessment
2030
FR
-Q13
FR
-Q12
FR
-Q11
FR
-Q1 4
0131
1100
3011
1210
2011
FR
-R1
FR
–D
2
FR Contribution toStrategic Dimension.
InnovativenessQualityCost
Volume flexibility
Top Management
Production Manager
Q11
Q12
Q13
Q14
R1
15
P1
T1
T2
T3
D1
D2
FR
Q11
Q12
Q13
Q14
R1
P1
T1
T2
T3
D1
D2
FR
FR
Production System Assessment and Definition of Strategic
Objectives
Training EffortInvestmentApplication
low high
…
…
…
…
...
...
…
…
…
...
...
FR-Q13
FR-T1
FR-D2
FR-Q11
FR-D1
FR-T2
FR-T3
FR-P1
FR-Q12
FR-Q14
FR-R1
Effort Prognosis lowmediumhigh
FR L
evel
Stra
tegi
c R
elev
ance
of F
RE
stim
ated
FR
effo
rtsInnovativenessQuality
Volume flexibility
FR L
evel
Strategic Relevancex
Comparing FR Level, Strategic Relevance of FR, and estimated FR efforts
Visualization for Decision Support
DB DB
24Technical University of Braunschweig | Institute of Machine Tools and Production Technology
> Introduction
> Challenges and current Situation of Production System Design
> Research Objectives
> Framework Approach for Production System Design
> Linking Systems Thinking and Life Cycle Thinking for Production System Design
> Frame of Reference for Production System Design
> Software Implementation of the Framework Approach
> Conceptual Structure and Information Flow of the Framework
> Overview of current State of Development
> Conclusion
OUTLINE
13
25Technical University of Braunschweig | Institute of Machine Tools and Production Technology
outputin-put
out-putoutput
inputinput
Assessment
Current Production System Type & Performance
Definition ofStrategy Set
Definition of strategicobjectives, change dr.
DiagnosisIdentification of
(strategic)Improvement
potentials
Consulting
ProvidingProd. System Design
Information
Database Input Data
Production SystemDecomposition
(PSD)
PSD-FR-Mappings:Strategy, Life Cycle,C.Driver, Organizat.
PSD Best PracticeAssessment
PSD-DP-Mappings:Methods,Tools., Efforts, Benefits
DP-related Knowledge
Information on Methods, Tools, ...
FR-relatedKnowledge
Depicting Expert Know-how
Production System Design Knowledge
Depicting Expert Know-how
PSD-DP-Informat.:Templates, Posters,
Guidelines
Operational DPInformation
Information on Methods, Tools, ...
HierarchicalPS DecompositionDepicting a specific type of production
system
Evaluation
Evaluation of differentpossible design
parameter
CONCEPTUAL STRUCTURE AND INFORMATION FLOW OF THE SOFTWARE FRAMEWORK
Production Management Input Data
1 2 3 4 5
26Technical University of Braunschweig | Institute of Machine Tools and Production Technology
SOFTWARE IMPLEMENTATION OF THE FRAMEWORK
STEP 1
> Assessment of the current state of the production system based on the fulfillment of functional requirements.
> Verbal descriptions are used to depict five different levels of FR achievement.
CurrentAssessment Questions
Assessment Answers depicting 5 different levels of achivement
Assessment Question List
Assessment
Current Production System Type & Performance
Definition ofStrategy Set
Definition of strategicobjectives, change dr.
DiagnosisIdentification of
(strategic)Improvement
potentials
Consulting
ProvidingProd. System Design
Information
Evaluation
Evaluation of differentpossible design
parameter
1
14
27Technical University of Braunschweig | Institute of Machine Tools and Production Technology
SOFTWARE IMPLEMENTATION OF THE FRAMEWORK
STEP 2
> Definition and weighting of the pursued production strategy in terms of strategic capability dimensions (e.g. costs, quality, dependability, volume flexibility, etc.).
> By weighting selected strategic dimensions, the strategic relevanceof specific FRs can be determined.
Intuitive Weighting of
strategicDimensions
Scale of Weighting
Selection ofStrategic
Dimensions
Assessment
Current Production System Type & Performance
Definition ofStrategy Set
Definition of strategicobjectives, change dr.
DiagnosisIdentification of
(strategic)Improvement
potentials
Consulting
ProvidingProd. System Design
Information
Evaluation
Evaluation of differentpossible design
parameter
2
28Technical University of Braunschweig | Institute of Machine Tools and Production Technology
SOFTWARE IMPLEMENTATION OF THE FRAMEWORK
STEP 3
> Derivation of critical Functional Requirements based on a Prioritization Matrix for improvement potentials.
> Critical FRs can be selected and their position within the Decomposition Tree can be analyzed.
Critical Functional
Requirements
Improvement Potential
Strategic Relevance
Selected critical FRs within the Decomposition
Assessment
Current Production System Type & Performance
Definition ofStrategy Set
Definition of strategicobjectives, change dr.
DiagnosisIdentification of
(strategic)Improvement
potentials
Consulting
ProvidingProd. System Design
Information
Evaluation
Evaluation of differentpossible design
parameter
3
15
29Technical University of Braunschweig | Institute of Machine Tools and Production Technology
SOFTWARE IMPLEMENTATION OF THE FRAMEWORK
STEP 4 & 5
> Derivation of appropriate Design Parameters (e.g. methods) for production systems improvement.
> Provision of information on expected efforts (time, costs, qualification, etc.) for implementation of design parameters.
> Appropriate Design Parameters can be added to the preliminary project collection list.
Selected critical Functional
Requirement
List of FR-associated
Design Parameters
Collection of preliminary FRs
Detailed Method Information Template
Assessment
Current Production System Type & Performance
Definition ofStrategy Set
Definition of strategicobjectives, change dr.
DiagnosisIdentification of
(strategic)Improvement
potentials
Consulting
ProvidingProd. System Design
Information
Evaluation
Evaluation of differentpossible design
parameter
4 5
30Technical University of Braunschweig | Institute of Machine Tools and Production Technology
SOFTWARE IMPLEMENTATION OF THE FRAMEWORK
STEP 4 & 5
> Cross-impact analysis of Design Parameters of the preliminary project list with respect to the current situation
> Analysis of fast, moderate, and slow working lever.
> Analysis of critical interdependenciesand interpretation of possible side-effects.
IV
V
Interpretation Network
1Degree of Activitylow high
1
1
2
3
4
23
45
67
8
5
6
7
8
I
II
III
low
high
Deg
ree
of C
ross
-link
age
IV
V
Interpretation Network
1Degree of Activitylow high
1
1
2
3
4
23
45
67
8
5
6
7
8
I
II
III
low
high
Deg
ree
of C
ross
-link
age
Fast working leverHigh momentumChange Management
I
Moderate working lever Catalyst for changes. Strategic Management
Slow working lever Framework for changes. f. Normative Management
Fast feedbacks Controlling of activities. Indicator for long-term dev.
Slow feedbacks Review of objectivesIndicator for quality
II
III
IV
V
Legend
Degree of Activity
GraphicalInterpretation
Net
Degree of Cross-Linkage
Assessment
Current Production System Type & Performance
Definition ofStrategy Set
Definition of strategicobjectives, change dr.
DiagnosisIdentification of
(strategic)Improvement
potentials
Consulting
ProvidingProd. System Design
Information
Evaluation
Evaluation of differentpossible design
parameter
4 5
16
31Technical University of Braunschweig | Institute of Machine Tools and Production Technology
> Introduction
> Challenges and current Situation of Production System Design
> Research Objectives
> Framework Approach for Production System Design
> Linking Systems Thinking and Life Cycle Thinking for Production System Design
> Frame of Reference for Production System Design
> Software Implementation of the Framework Approach
> Conceptual Structure and Information Flow of the Framework
> Overview of current State of Development
> Conclusion
OUTLINE
32Technical University of Braunschweig | Institute of Machine Tools and Production Technology
CONCLUSION
> The integration of Strategic and Life Cycle oriented requirements into the Production System planning process are a key to successful Lean Production System Design.
> The presented Framework approach supports a systemic and life cycle oriented improvement process of Lean Production Systems.
> The Software prototype supports companies to derive adequate Design Parameters with respect to their current situation, strategy and company-internal interdependencies.
> In the next steps, the software prototype will be evaluated and tested in production companies.
CONCLUSION
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33Technical University of Braunschweig | Institute of Machine Tools and Production Technology
Framework For Life Cycle Oriented Production System Design
Liverpool, 31th May 2007
40th CIRP International Seminar on Manufacturing Systems
May 30th – June 1st, 2007, Liverpool, UK
Christoph HerrmannLars BergmannAndré Zein