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The House of Maintenance
(2009)
In order to guarantee an efficient and effective employment of production equipment, it is essential to identify any possible potential for improving performance, not only in the production process, but also in supporting areas such as maintenance. One of the major tasks in increasing maintenance performance consists of systematically identifying the company’s most significant weaknesses in maintenance organisation and thus being able to implement improvements there where they are most needed.
But how is a company to tackle this important task? To answer this question, this paper describes an assessment and improvement approach, based on a capability maturity model (CMM). By means of this approach, the status-quo of a maintenance organisation can be analysed and its individual improvement opportunities identified.
Due to shorter product life cycles the number of production ramp-ups is increasing, while customers have a soaring demand for more variable and individualized products. In the future, optimizing the production ramp-up will become an important differentiation criterion for companies. Considering the whole supply chain in the ramp-up process becomes therefore indispensable. This is what the presented research in this paper concentrates on. The intention of the research project is to develop a model of a supply chain in the production ramp-up stage. Through this model, approaches for optimizing the production ramp-up in the whole supply chain will be derived.
Further the research project concentrates on measuring the production ramp-up performance in the supply chain, showing the impact on economic and financial measures. The result of this research is an approach to align the tasks and objectives of Supply Chain Management with the tasks and objectives of ramp-up management in order to optimize the whole supply chain in the ramp-up stage.
The Aim of this article is to provide a framework which enhances the existing scope of manufacturing asset management by specifically addressing industrial services provided by external suppliers as an integral part of today’s manufacturing structures. Existing research shows that sourcing industrial services from specialized service organizations establishes complex and unique interdependencies and links total production efficiency to the performance of the external service suppliers. Within the context of the EU-Project InCoCo-S - “Innovation, Coordination and Collaboration in Service Driven Manufacturing Supply Chains” a standard business reference model with key focus on operation and integration of business related services (BRS) in the supply chain has been developed. Based on the service type retrofit this paper aims on the one hand to present the modules of the reference model and on the other hand to explain how the model can be used to enhance the retrofit business.
Outsourcing of logistics operations (especially transportation, distribution & warehousing) is one of the most viable options exercised by the customers to excel in their logistic operations. Despite the growing outsourcing of logistics services to 3PL providers, both the service providers & their customers are facing tremendous problems in synchronizing the business processes & analyzing the performance using common key performance indicators. There is a huge demand for an integrated approach to help 3PL and their customers better synchronize their business processes and have common goals & perspectives. Such integrated approaches often take shape of a process oriented reference model covering many diverse aspects related to the operations & controlling of any business. In this paper, an integrated reference model to support 3PL service operations is presented. The Logistics Reference Model (LRM) developed & validated in some 3PL service companies encompasses standard business processes, performance measurement system and best practices.
In most European countries a structural change from a production dominated towards a service oriented society is progressing. Companies increasingly consider services as means to gain competitive advantages in a global competition. In order to provide holistic, value-adding solutions while simultaneously guaranteeing high quality standards, production companies increasingly join forces with external services‘ providers. Models, methods and tools for service development are rare and in most cases immature. In the context of virtual services‘ development this leads to a dual set of simultaneous chal-lenges: an alignment of systematic services‘ and product development and the coordination of distributed R&D partners. The objective is to provide a meta-process that identifies all steps and decision points necessary to successfully develop innovative services. It is a result of combined service development and virtual enterprises‘/ networks‘ research.
Gap Analysis for CO2 Accounting Tool by Integrating Enterprise Resource Planning System Information
(2023)
Detailed carbon accounting is the foundation for reducing CO2 emissions in manufacturing companies. However, existing accounting approaches are primarily based on manual data preparation, although manufacturing companies already have a variety of IT systems and resulting data available. The gap analysis carried out based on the GHG Protocol and an reference ERP system shows how much of the required information for CO2 accounting can be integrated from an ERP system. The ERP system can cover 20 % of the required information. The information availability can be increased to 49 % through additionally identified modifications of the ERP system. Integrating the CO2 accounting tool with other systems of the IT landscape, e. g. Energy Information System, enables an additional increase.
Manufacturing companies face the challenge of managing vast amounts of unstructured data generated by various sources such as social media, customer feedback, product reviews, and supplier data. Text-mining technology, a branch of data mining and natural language processing, provides a solution to extract valuable insights from unstructured data, enabling manufacturing companies to make informed decisions and improve their processes. Despite the potential benefits of text mining technology, many manufacturing companies struggle to implement use cases due to various reasons. Therefore, the project VoBAKI (IGF-Project No.: 22009 N) aims to enable manufacturing companies to identify and implement text mining use cases in their processes and decision-making processes. The paper presents an analysis of text mining use cases in manufacturing companies using Mayring's content analysis and case study research. The study aims to explore how text mining technology can be effectively used in improving production processes and decision-making in manufacturing companies.
With the development of publicly accessible broker systems within the last decade, the complexity of data-driven ecosystems is expected to become manageable for self-managed digitalisation. Having identified event-driven IT-architectures as a suitable solution for the architectural requirements of Industry 4.0, the producing industry is now offered a relevant alternative to prominent third-party ecosystems. Although the technical components are readily available, the realisation of an event-driven IT-architecture in production is often hindered by a lack of reference projects, and hence uncertainty about its success and risks. The research institute FIR and IT-expert synyx are thus developing an event-driven IT-architecture in the Center Smart Logistics' producing factory, which is designed to be a multi-agent testbed for members of the cluster. With the experience gained in industrial projects, a target IT-architecture was conceptualised that proposes a solution for a self-managed data-ecosystem based on open-source technologies. With the iterative integration of factory-relevant Industry 4.0 use cases, the target is continuously realised and validated. The paper presents the developed solution for a self-managed event-driven IT-architecture and presents the implications of the decisions made. Furthermore, the progress of two use cases, namely an IT-OT-integration and a smart product demonstrator for the research project BlueSAM, are presented to highlight the iterative technical implementability and merits, enabled by the architecture.
More and more companies in the mechanical and plant engineering industry are transforming their business model and evolving from product to solution providers. Subscription business models play a key role in this development. They enable companies to enter long-term collaborative relationships with customers and thus monetize the potential of Industry 4.0. However, this development is not easy for many companies and is associated with numerous hurdles. One of these hurdles is the development of a suitable range of services tailored to customer needs. In this context, the bundling of individual services to service modules plays a key role in realizing new value propositions. In practice, however, companies often lack an understanding of which services need to be combined in what way to be able to realize new value propositions. Accordingly, the goal of this work is to identify relevant services for subscription business models, to cluster them into meaningful value-adding bundles, and to derive new value propositions accordingly. The new value propositions in turn enable mechanical and plant engineering companies to strengthen customer loyalty and thus achieve long-term economic success.
A large number of product-accompanying services in the machinery and plant engineering industry is based on the cross-company exchange of data and information. By providing services, additional sales potential on the manufacturer side as well as far-reaching product and process advantages for appliers can be reached. However, the necessary cross-company exchange of information is nowadays limited due to a lack of trust in the interacting partner and the applicable existing technologies, which results in significant losses in the terms of business potential. The uncovering of this potential now seems to be made possible by the use of the Blockchain technology. Through the key factors security, immutability, transparency and decentralisation, it serves as an enabler for cross-company communication and product-accompanying services. The technological implementation of a Blockchain can take on a broad spectrum of attributes, which can lead to decisive restrictions for the execution of services. This justifies the necessity for a qualified and context-related assessment of service-types-individual specifications and the resulting requirements on the system. Within the scope of this paper, different types of product-accompanying services are identified and analysed regarding their requirements for a Blockchain-based machinery and plant connection. This can serve as a basis for a qualified and goal-oriented configuration of the Blockchain.
Digital networking via the company and as well, the overall supply chain, can only succeed if digital planning reflects reality as accurately as possible and if production control can react to deviations in real time. In essence, this leads to a development of process control towards process regulation. While longterm production and resource planning is usually mapped by Enterprise Resource Planning (ERP) systems, detailed planning, including short-term deviations and real-time data at the production level, is increasingly supported by Manufacturing Execution Systems (MES) at the production control level. However, in order to bring the underlying system concepts into line with Industry 4.0 efforts in a standardized manner, mutual functional integration within the framework of interoperable production planning and control is of crucial importance. For this purpose, studies were carried out in particular into cause-effect relationships. Thus, the overarching research objective is a valid design model to increase the controllability of production planning and control systems (PPC) in the context of Industry 4.0.
Smartification and digital refinement of products to enable the design of smart ones is a pivotal challenge in the manufacturing industry. Companies fail to design smart products due to missing knowledge of digital technologies and their integral part in product development processes. This paper presents a methodology that enables the derivation of digital functions for smart products through selected cases in manufacturing usage. We develop a morphology that consists of digital functions for smartification. In this context, we explained and derived characteristics by a set of examples regarding smart products in the manufacturing industry. Our methodology reduces the time spent initiating a development project with the focus on smartification.
The planning and implementation of migration projects in global production networks is a complex planning task that is confronted with a dynamic global environment with highly complex interdependencies. Today's migration approaches are either large projects or isolated local
investments. As such, they are not suitable for simultaneously addressing interdependencies and continuity. This paper illustrates a holistic and continuous methodology for rolling migration planning and implementation in global production networks. Seven steps enable the transformation from the current state of the production network into a target state regarding internal as well as external dynamics and interactions.
The number of cyber-attacks on small and medium enterprises (SMEs) is constantly increasing. SMEs do not recognize the attacks until the damage has occurred. Only then, they fight with measures to increase IT-security and IT-safety. Many studies come to the point that this refers to a lack of budget, expertise and awareness of the need for IT-security. There are many compendia with recommendations for action, but they are too comprehensive and unspecific to the individual needs of SMEs. In this paper, we present the results of a research activity on the gaps that address the challenges faced by SMEs. In addition, we develop a concept for a serious gaming approach that includes an economic perspective on IT-security measures and shows how SMEs can derive their own IT-seurity target state
Manufacturing companies face the challenge of selecting digitalization measures that fit their strategy. Measures that are initiated and not aligned with the company’s strategy carry the risk of failing due to lack of relevance. This leads to an ineffective use of scarce human and financial resources. This paper presents a target system to help companies select relevant digitalization measures compliant with their strategy for IT-OT-integration projects. The target system was developed based on literature research and expert interviews, and later validated in two use cases. The target system considers the goals of production companies and combines them with digitalization measures. The measures are classified by different maturity levels required for their realization. Thus, the target system enables manufacturing companies to evaluate digitalization measures with regards to their strategic relevance and the required Industrie 4.0 maturity level for their realization. This ensures an effective use of resources.
The number of available technologies is constantly rising. Be it additive manufacturing, artificial intelligence (AI) or distributed ledger technologies. The choice of the right technologies may decide the fate of a company. Due to the overwhelming amount of information sources, regular technology market research becomes increasingly challenging, especially for SMEs. In order to assist the technology management process, the authors will introduce the architecture of an automated, AI-based technology radar. The architecture will automatically collect data from relevant sources, assess the relevance of the respective technology (i.e. their maturity level) and then visualize it on the radar map.
Numerous traditional, agile and hybrid development approaches have been proposed for the development of CPS. As the choice of development process is crucial to the success of development projects, it has become a major challenge to identify the best-suited process. This paper introduces a methodology for identifying the best-suited CPS development process, based on the individual boundary conditions for a certain development project within a company. The authors used a set of eight indicators to assess a CPS-development project. The results of the assessment were matched with CPS-development approaches. Based on the matching results a best-suited development process was selected. The application is shown for a use case in the German manufacturing industry. The developed method aims to reduce the risk of project failure due to the wrong choice of development process.
Auf Basis einer systematischen Literaturanalyse wurden insgesamt 11 Kennzahlen identifiziert, welche die Grundlage zur Beschreibung der operativen Leistungsfähigkeit von Unternehmen bilden. Die Kennzahlen wurden in die vier Leistungsdimensionen Effizienz, Qualität, Zeit und Flexibilität eingeteilt.
Methods of machine learning (ML) are difficult for manufacturing companies to employ productively. Data science is not their core skill, and acquiring talent is expensive. Automated machine learning (Auto-ML) aims to alleviate this, democratizing machine learning by introducing elements such as low-code or no-code functionalities into its model creation process. Due to the dynamic vendor market of Auto-ML, it is difficult for manufacturing companies to successfully implement this technology. Different solutions as well as constantly changing requirements and functional scopes make a correct software selection difficult. This paper aims to alleviate said challenge by providing a longlist of requirements that companies should pay attention to when selecting a solution for their use case. The paper is part of a larger research effort, in which a structured selection process for Auto-ML solutions in manufacturing companies is designed. The longlist itself is the result of six case studies of different manufacturing companies, following the method of case study research by Eisenhardt. A total of 75 distinct requirements were identified, spanning the entire machine learning and modeling pipeline.
More and more manufacturing companies are starting to transform the transaction-based business model into a customer value-based subscription business to monetize the potential of digitization in times of saturated markets. However, historically evolved, linear acquisition processes, focusing the transactionoriented product sales, prevent this development substantially. Elemental features of the subscription business such as recurring payments, short-term release cycles, data-driven learning, and a focus on customer success are not considered in this approach. Since existing transactional-driven acquisition approaches are not successfully applicable to the subscription business, a systematic approach to an acquisition cycle of the subscription business in the manufacturing industry is presented, aiming at a long-term participative business. Applying a grounded theory approach, a task-oriented model for themanufacturing industry was developed.
The model consisting of five main tasks and 14 basis tasks serves as best practice to support manufacturing companies in adapting or redesigning acquisition activities for their subscription business models.