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Task-Specific Decision Support Systems in Multi-Level Production Systems based on the digital shadow
(2019)
Due to the increasing spread of Information and Communication Technologies (ICT) suitable for shop floors, the production environment can more easily be digitally connected to the various decision making levels of a production system. This connectivity as well as an increasing availability of high-resolution feedback data, can be used for decision support for all levels of the company and supply chain. To enable data driven decision support, different data sources were structured and linked. The data was combined in task-specific digital shadows, selecting clustering and aggregation rules to gain information. Visual interfaces for task-specific decision support systems (DSS) were developed and evaluated positively by domain experts. The complexity of decision making on different levels was successfully reduced as an effect of the processed amounts of data. These interfaces support decision making, but can additionally be improved if DSS are extended with smart agents as proposed in the Internet of Production.
Service Engineering Models
(2019)
Since the field of service engineering emerged in the late 20th century, the service industry has undergone drastic changes. Among the reasons for these changes is the increasing digitalization, which has made it difficult for companies to successfully develop new service offerings. While numerous service engineering models are available to provide guidance during the design of new services, many of them cannot keep up with the requirements of today’s economic environment. The present paper examines the requirements that service engineering models need to meet in order to be suitable guidelines for the digital age. To this end, the introduction illustrates how digitalization has changed the service industry. Afterwards, selected service engineering models and related norms are presented. Finally, a set of requirements for modern service engineering models derived from best practices from recent years is introduced.
Due to Digital Transformation, also called Industry 4.0 or the Industrial Internet of Things, the barrier for implementing data collecting technology on the shop floor has decreased dramatically in the past years – leading to an increasingly growing amount of data from a multitude of IT systems in production companies worldwide. Despite that, the production controller still relies heavily on intrinsic knowledge and intuition for the management of disruptions in production. Thanks to advances in the fields of production control and artificial intelligence, potentials for the collected data for disruption management arise. However, in order to transform data into usable information and allow drawing conclusions for disruption management in production, the relevant data-objects, disturbances and alternative actions must be known. Thus, the decision-making can be supported, reducing the decision latency and increasing benefit of alternative actions. Therefore, the goal of this paper is to discuss the prerequisites necessary to perform a data based disruption management and the methodology itself, serving as an approach to allow companies to build a data basis, classify disruptions and alternative actions in order to improve decision making in the future. [https://link.springer.com/chapter/10.1007/978-3-030-28464-0_13]
Smart Service Engineering
(2019)
In our digitalized economy, many traditional service engineering models lack flexibility, efficiency and adaptability. As today’s market differs significantly from the market of the late 20th century, service engineering models must meet different requirements today than they had to meet in the past. The present paper starts off by providing an overview of the requirements that modern service engineering models need to fulfill in order to succeed in today’s economic environment. Afterwards, three promising models that meet several of these requirements will be introduced.
Nowadays, the market for information and communication technologies used for IOT-applications grows daily. Since companies need technologies to transform their business processes corresponding to the digital revolution, they need to know which technologies are available, and fit the best for their use case. Their inertial issue is the lacking overview of technologies suitable to connect their production or logistics. Hence, this paper presents a methodology to select technologies (and combinations) based on their functions. It differentiates between information and communication technologies, digital technologies and connecting technologies by the physical function and its role in a cyber-physical system. Depending on the use case, the applicability of every technology varies. Due to that reason, the paper illustrates a ranked qualification of the technologies for typical use cases, focussing tracking and tracing issues in the intralogistics of producing companies. The evaluation is performed upon a literature research, a market study to identify suitable technologies, and various expert interviews to assess the applicability of the technologies.
Many ERP systems support configurable materials. Due to an ever increasing number of product variants the benefits of this approach are well understood. However, these implementations are not standardized. In this article we propose a new standard interface for the exchange of configuration data. This would lead to further benefits as systems as Advanced Planning systems could better use manufacturing flexibility while web shops as Amazon could easily integrate manufacturers of complex products with much reduced implementation effort.
Towards the Generation of Setup Matrices from Route Sheets and Feedback Data with Data Analytics
(2018)
The function or department of production control in manufacturing companies deals with short-term scheduling of orders and the management of deviations during order execution. Depending on the equipment and characteristics of orders, sequence dependent setup times might occur. In these cases for companies that focus on high utilization of their assets due to long phases of ramp up and high energy costs, it might be optimal to choose sequences with minimal setup time times between orders. Identifying such sequences requires detailed and correct information regarding the specific setup times. With increasing product variety and shorter lot sizes, it becomes more difficult and rather time intense to determine these values manually. One approach is to analyse the relevant features of the orders described in the route sheets or recipes to find similarities in materials and required tools. This paper presents a methodology, which supports setup optimized sequencing for sequence dependent setup times through constructing the setup matrix from such route sheets with the use of data analytics.
Manufacturing companies worldwide recognized the high potential of Industrie 4.0 in order to increasing production efficiency. Key benefits include creation of integrated systems, networked products and improvement of service portfolios. However, for many companies deriving and evaluating necessary measures to use Industrie 4.0 potentials represents a major challenge. This paper introduces the "acatech Industrie 4.0 Maturity Index" as an approach to meet this challenge. The development of multidimensional maturity model intents to provide companies an assessment methodology. The aim is to capture the status quo in companies in order to be able to develop individual roadmaps for the successful introduction of Industrie 4.0 and manage the transformation progressively.
Factory automation and production are currently
undergoing massive changes, and 5G is considered being a key
enabler. In this paper, we state uses cases for using 5G in the
factory of the future, which are motivated by actual needs of the
industry partners of the “5Gang” consortium. Based on these use
cases and the ones by 3GPP, a 5G system architecture for the
factory of the future is proposed. It is set in relation to existing
architectural frameworks.
Digitalization is changing the industrial landscape in a way we did not anticipate. The manufacturing industries worldwide are working to develop strategies and concepts for what is labelled with different terms such as the Industrial Internet of Things in the USA or Industrie 4.0 in Germany. Many industrialized economies are driven by the production sector and this sector needs specific approaches and instruments to take up other than those approaches we know from start-ups and ventures coming from Silicon Valley and other places. In this paper, we demonstrate an appropriate approach to transform producing companies in a systematic and evolutionary approach.
In particular, the objective of this paper is to provide results from two initiatives which conceptually build upon each other and are of particular relevance for the production industry. First, we present a global survey on the state of implementation and the future perspectives of the concept Industrie 4.0 from 2016. Findings from this study have forced parts of the German industry to heavily invest into a common approach to accelerate change towards Industry 4.0 in order to stay competitive in worldwide economy. This approach is presented in a second part.
This paper addresses the challenge of modelling individual cyber-physical systems (CPS) for small and medium-sized enterprises (SMEs) in manufacturing industries. CPS are key technology building blocks for the implementation of Industrie 4.0. Especially for SMEs the increase of production efficiency and reduction of manufacturing costs through CPS offer potential to maintain their competitiveness and innovation capacity. Although SMEs perceive the potential of CPS, they often lack financial and human resources to acquire the necessary CPS-competencies as well as an overview of all the currently available technological solutions. To overcome this issue a matching platform will offer SMEs support in finding suitable CPS-components by letting them express their functional and technical requirements. The matching logic is based on a set of morphologies that encompasses the functional and requirement spectrum of CPS-components. The matching algorithm analyses the input for congruence of requirements and available technologies and suggests suitable technology combinations. This paper describes the methodology of the matching platform, and introduces the research work to define and to develop the technology morphologies. The presented results facilitate the selection and configuration of CPS for SMEs.
Influenced by the high dynamic of the markets and the steadily increasing demand for short delivery times the importance of supply chain optimization is growing. In particular, the order process plays a central role in achieving short delivery times and constantly needs to evaluate the trade-off between high inventory and the risk of stock-outs. However, analyzing different order strategies and the influence of various production parameters is difficult to achieve in industrial practice. Therefore, simulations of supply chains are used in order to improve processes in the whole value chain. The objective of this research is to evaluate two different order strategies (t, q, t, S) in a four-stage supply chain. In order to measure the performance of the supply chain the quantity of the backlog will be considered. A Design of Experiments approach is supposed to enhance the significance of the simulation results.
Die Verschärfung des Wettbewerbsumfelds produzierender Unternehmen und die als Antwort hierauf in den Fokus rückenden agilen Methoden vergrößern die Bedeutung einer effizienten Handhabung von Änderungsprozessen. Am Beispiel des Maschinen- und Anlagenbauers Ortlinghaus zeigt der Beitrag, dass eine Kombination aus ungeeigneten Änderungsprozessen und mangelhaftem IT-Support in der Praxis oft die schnelle und gleichzeitig qualitätsgesicherte Durchführung von Änderungsprozessen verhindert. Der Zielkonflikt aus geringem Zeitbedarf und hoher Prozessqualität lässt sich durch Anpassungen in der IT-Unterstützung reduzieren. Hierdurch können Erfolgsfaktoren für ein effizientes Änderungsmanagement gehoben und die Problemfelder der Workflowunterstützung, Informationsverteilung und Datenhandhabung verbessert werden. Zentrales Hindernis zur Adressierung der Erfolgsfaktoren stellt die aktuell zur Abwicklung von Change Requests genutzte Arbeitsumgebung dar. Der Beitrag präsentiert hierfür als zentralen Lösungsansatz die Internet of Production Infrastruktur. Das Potenzial der Internet of Production Infrastruktur im Kontext des Änderungsmanagements wird anhand von drei Anwendungsbeispielen verdeutlicht. Abschließend wird der Migrationspfad für Unternehmen bei der Einführung eines effizienten Änderungsmanagements aufgezeigt.
Industrie 4.0 is changing the industrial landscape in an unanticipated way. The vision for manufacturing industries is to transform to an agile company, in order to react on occurring events in real-time and make data based decisions. The realization requires also new capabilities for the information management. To achieve this goal agile companies require taking measured data, analyzing it, deriving knowledge out of this and support with the knowledge their employees. This is crucial for a successful Industrie 4.0 implementation, but many manufacturing companies struggling with these requirements. This paper identifies the required capabilities for the information management to achieve a successful Industrie 4.0 implementation. [https://link.springer.com/chapter/10.1007/978-3-319-65151-4_3]
Nowadays, cyber physical systems support the improvement of efficiency in intralogistics by controlling and manipulating the production and logistic environment autonomously. Due to the complexity of the individual production processes, designing suitable cyber-physical systems based on their existing production environment is a challenge for companies.
This paper presents a new methodology on how to design cyber-physical systems conceptually to suit an individual production environment. Compared to existing design approaches, this methodology matches immediately the required functions to existing information and communication technology’s components insisting on the neutral assimilation of requirements.
Therefore, the requirement specification asks for needed functions in relating to offered functions of information and communication technology (ICT) components. The paper focusses the use case of implementing a cutting-edge mobile network technology into an existing tracking and tracing process.
With big data-technologies on the rise, new fields of application appear in terms of analyzing data to find new relationships for improving process under-standing and stability. Manufacturing companies oftentimes cope with a high number of deviations but struggle to solve them with less effort. The research project BigPro aims to develop a methodology for implementing counter measures to disturbances and deviations derived from big data. This paper proposes a methodology for practitioners to assess predefined counter measures. It consists of a morphology with several criterions that can have a certain characteristic. Those are then combined with a weighting factor to assess the feasibility of the counter measure for prioritization.
Influenced by the high dynamic of the markets the optimization of supply chains gains more importance. However, analyzing different procurement strategies and the influence of various production parameters is difficult to achieve in industrial practice. Therefore, simulations of supply chains are used in order to improve the production process. The objective of this research is to evaluate different procurement strategies in a four-stage supply chain. Besides, this research aims to identify main influencing factors on the supply chain’s performance. The performance of the supply chain is measured by means of back orders (backlog). A scenario analysis of different customer demands and a Design of Experiments analysis enhance the significance of the simulation results.
Failure management in the production area has been intensely analyzed in the research community. Although several efficient methods have been developed and partially successfully implemented, producing companies still face a lot of challenges. The resulting main question is how manufacturers can be assisted by a sustainable approach enabling them to proactively detect and prevent failures before they occur. A high-resolution production system based on analyzed real-time data enables manufacturers to find an answer to the main question. In this context, Big Data technologies have gained importance since the critical success factor is not only to collect real-time data in the production but also to structure the data. Therefore, we present in this paper the implementation of Big Data technologies in the production area using the example of an actual research project. After the literature review, we describe a Big Data based approach to prevent failures in the production area. This approach mainly includes a real-time capable platform including complex event processing algorithms to define appropriate improvement measures.
Increasing the energy efficiency and meanwhile avoiding unplanned maintenance breaks are keys for manufacturing companies to stay competitive in the future. This paper presents an energy saving and maintenance cost reducing approach for manufacturing environments. The approach describes first occurring types of energy wastage within manufacturing and characterizes them in more detail. Including additional external information, the significance of an identified on-going wastage can be determined. Based on the type of wastage and the significance; concrete recommendations for measures to prevent the wastage are delivered. The identified wastage facilitates detecting inefficient operating mode as well as wearing and malfunctioning at machines. By using complex event processing technologies realtime information can forwarded directly to the responsible persons to enable quick reactions to prevent energy wastage and unplanned downtimes. The paper presents an approach to identify detection and propose concepts for manufacturing enterprises. The information processing procedure is used for the implementation of two Use Cases.
In recent years supply chain participants are increasingly suffering the effects of disturbances in transportation supply chains. Both, dynamics in consumer demands and global supply chains lead to a growth in unplanned supply chain events. These can cause from rather manageable disturbances through to complete break-downs of transportation chains, resulting in high follow-up and penalty costs.
Consequently, concepts for an efficient supply chain disturbance management are needed, preferably with a real-time identification and reaction to disturbance events. Therefore in the following paper the research results of the German research project Smart Logistic Grids with the focus on designing an integrated model for the real-time disturbance management in transportation supply networks are presented. This includes the introduction of elaborated classification models for disturbances and action patterns as well as an associated costs and performance measurement system. Finally, a procedure model for the disturbance management is presented.
Aufgrund kürzer werdender Produktzyklen und steigender Produktvielfalt werden produzierende Unternehmen mit einer zunehmenden Anzahl von Produktanläufen konfrontiert. Ziel aktueller Forschungsaktivitäten ist es daher, anlaufintensive Unternehmen zu befähigen, verlässliche Produktionsprogramme in kurzer Zeit zu erstellen. Lerneffekte sollen genutzt werden können ohne Diversifikationseffekte zu vernachlässigen. Zur Erreichung dieser Zielsetzung wird ein Modell für eine kybernetische PPP bei Produktanläufen entwickelt.
High Resolution Supply Chain Management aims to counteract the trend towards more and more centralised and rigid enterprises. Today, most companies strive to increase efficiency of business processes applying highly sophisticated, centralised planning approaches. These centralised approaches limit the companies’ ability to react flexibly and act adaptively due to external and internal turbulences. In today’s buyer’s markets companies usually try to bypass these turbulences keeping high levels of inventory resulting in a low overall efficiency. High Resolution Supply Chain Management tries to solve the problem at its root from a holistic perspective. Based on the Viable System Model developed by Stafford Beer a four-dimensional holistic production management system model, embedding an organisational structure view, an cause and action view, a control loop perspective and a decision making level has been elaborated. The basis of this model is the integration of all four perspectives into an interacting framework.
High Resolution Supply Chain Management (HRSCM) aims to stop the trend of continuously increasing planning complexity. Today, companies in high-wage countries mostly strive for further optimization of their processes with sophisticated, capital-intensive planning approaches. The capability to adapt flexibly to dynamically changing conditions is limited by the inflexible and centralized planning logic. Thus, flexibility is reached currently by expensive inventory stocks and overcapacities in order to cope with rescheduling of supply or delivery. HRSCM describes the establishment of a complete information transparency in supply chains with the goal of assuring the availability of goods through decentralized, self-optimizing control loops for Production Planning and Control (PPC). HRSCM pursues the idea of enabling organization structures and processes to adapt to dynamic conditions. The approach includes the strengths of the existing planning models as well as the process of decision making in organizations. A precondition for this decentralized adaptation is the synchronization of the objectives of the several units or process owners. The basis for this new PPC Model are information transparency, stable processes, consistent customer orientation, increased capacity flexibility and the understanding of the production system as a viable, socio-technical system.
Analysis of the Harmonizing Potential of Order Processing Attributes in Spread Production Systems
(2010)
The paper discusses an approach how to measure the competitive advantage of harmonized order processing data by making use of knowledge about the interdependencies between related benefit dimensions. Corresponding harmonization projects are all projects that strive for common structures in product attributes, classification systems or product structures. The main objective of the underlying research work is the development of a method for the estimation of the benefit potential of harmonized order processing data.
Viable Production System for adaptable and flexible production planning and control processes
(2009)
High Resolution Supply Chain Management (HRSCM) aims at designing adaptable and flexible production planning and control (PPC) processes according to the needs of the company’s supply chain environment. To reach this goal a model for a Viable Production System (VPS) has been elaborated and is presented in this paper. Based on the Viable System Model (VSM) developed by Stafford Beer current production systems are analyzed in terms of integrity. With the gained knowledge a complete recursive framework of a VPS is developed. The framework allows the design of a decentralized production system that meets all requirements of a dynamic environment. Flexible and adaptable PPC processes can be developed for each identified subsystem of the VPS. Hence, further research focuses on the development of process and control loops in order to assure the application of the framework. Exemplarily the decentralised control loop for inventory management is elaborated in a case study.
Supply Chain Management delivers a considerable amount of ideas and methods to design the value stream. Each of these concepts may lead to significant cost reduction and higher service levels. But the same concept does not work for different customers and their diverse needs. Thus, a “one size fits it all” supply chain cannot lead to success. The key to overcome this obstacle is the hybrid supply chain. This paper outlines the application of hybrid system theory to supply chains. After a comprehensive overview of existing methods for the design of supply chains is given, a methodology for a customer-to-customer oriented supply chain design is presented. This approach adopts the hybrid system theory to supply chains which is in a nutshell that hybrid systems use the advantages of its subsystems to reach a superior result to one system alone. Concluding a case study illustrates the application of the methodology.