The production ramp-up is often a critical period for manufacturing companies. With a developed method for planning and monitoring of production ramp-ups at new locations this critical period becomes manageable. The method consists of reference processes, key figures and reactions. By different aggregation levels a target-actual comparison can be made to identify appropriate reactions.
production ramp-up, maturity model, aggregation logic, ramp-up management
Using hybrid forging techniques, both bulk or sheet metal can be formed and joined in a single step, rendering subsequent joining processes unnecessary. Moreover, using sheet metal rather than bulk material means that material-savings can be made and/or more economical forming units can be used.
hybrid, forging, sheet metal forming, joining technology, steel, adhesive bond
The production of a flashless crankshaft consists of four steps: cross wedge rolling, lateral extrusion, bi-directional forging and final forming. One improvement is to shorten the process by leaving out the lateral extrusion which leads to different faults as folds and flash. To investigate the influence of the cross wedge rolling on the bi-directional forging serval process parameters as forming angle and offset of the axis were varied. The purpose is to find a parameter field in which to faults occur.
cross wedge rolling, multi-directional forging, crankshaft forging without flash
There is a high potential for optimization in positioning a forging company’s tool supply between logistic costs and performance. Based on a model, which was developed for the improvement of the internal tool supply in the transfer project T13 of the CRC 489, a controlling instrument has been deduced to relate the weighted service level and the stock of the tool supply cycle.
production planning and -steering, production management, tool inventory reduction, servicelevel, fo
Designing a road layout for automated guided vehicles (AGV) can be a very laborious process that is based in big parts upon the knowledge of experienced system planers. Up until now, it isn’t possible to save that knowledge in a form that makes it usable in an automated layout process for AGV- roadmaps. The research project aims to integrate the knowledge of the system planers in an artificial intelligence, so that in the future an automated process of designing AGV roadmaps is achievable. The knowledge is implemented within a fuzzy-logic and can be used as a controller for the planning process.
automated guided vehicles, expert system, fuzzy logic, fuzzy logic controller
Intensive research work on flashless precision forging of steel materials has been made at the IPH in the past. In aluminum forging processes a thin flash often occurs in the gap areas between the forming elements. This thin flash adversely affects the component quality. For this reason flashless aluminum forging previously could not be realized. In this publication, the approach for the investigation of the thin flash formation is explained. A FEM model of a one-stage upsetting process in a closed die has been created. With this model the influence of the parameters workpiece temperature, forming velocity, the wideness of the flash gap and the pressing forces on the thin flash formation can be examined. Owing to these research activities a possibility for aluminum forging without flash and thin flash shall be provided.
flashless, forging, thin flash, aluminum, FEA
Rising costs for electricity endanger the competitiveness of the German industry. If the volatility of electricity prices and fluctuating energy consumptions are used purposefully by the manufacturing control, a reduction of energy costs without capital-intensive investments is possible. In this context the following article describes the development of a sequencing method considering work order-specific energy costs.
time variable electricity prices, fluctuating energy consumptions, manufacturing control, sequencing
The first challenge in the planning process of production systems is the creation of a rough draft of the system with minimal time and cost. From this an offer for the customer is then derived. This article describes a model-based approach for rough planning and its demonstrative implementation. The approach allows modeling at a high abstraction level. This reduces the modeling effort, the possible modeling errors and the documentation effort considerably.
production system, operations planning, performance prediction, simulation, variant documentation
The complaint handling suffers from defective 8D-reports. Hence the costumer supplier relationship is also affected. A system for the formal and substantive evaluation of 8D-reports will be developed in a research project. The aim is to improve the complaint processing due to high quality 8D-reports.
8d-method, 8d-report, claims management, complaint, quality management
Preforming is an essential step in flashless forging processes. This paper describes the development of a four stage process chain for flashless forging of a crankshaft with pin and flange. The process consists of cross wedge rolling, lateral extrusion, bi-directional forging and final forming. The finite-element-analysis (FEA) performed with the software Forge 3 and experimental tests are executed with different process parameters, like billet and tool temperature, rolling velocity and steel. To reduce process steps, like lateral extrusion, a direct combination of cross wedge rolling and bidirectional forging is analysed with FEA-software Forge 3 for a one cylinder crankshaft without pin and flange. The results of the FEA give suitable forming angles alpha for cross wedge rolling and several geometric parameters for a modification of the bi-directional tool.
cross wedge rolling, bi-directional forging, crankshaft forging without flash, preforming
By leveraging the production factor "human" it is possible by taking into account human performance fluctuations during the day to reduce product-related defect costs and increase quality. To this end, the integration of human performance variations in methods of production planning and control must be carried out. This article introduces a method by which a quality-oriented job shop schedule can be created, taking into account human performance fluctuations.
produktion planning, job shop scheduling, human performance fluctuation, optimization problem
Will the freight depot still be large enough in ten years – or is it necessary to built new rails? An austrian company wanted an answer to this question – and IPH was able to help with a detailed material flow simulation.
material flow simulation, railway traffic
An analysis of lifecycle data offers the potential to identify product weaknesses and starting points for product innovations. The paper describes a concept to analyze lifecycle data using predefined analyses and interactive searches. Moreover, a concept to integrate the results of the data analysis into an existing software environment is presented.
data-mining, life-cycle-data, data analysis, knowledge akquisition
While definitions already exist for smaller scale device structures e. g. nanotechnology, the conceptual distinction between standard large products and large scale or XXL products is currently insufficient. This study presents a basic definition of large scale products. At first hypotheses are being derived and examined at an empirical study of three sample products threaded nuts, screw presses and passenger aircrafts. It will be shown that the transition from conventional products to XXL large scale products is characterized by a disproportionate increase in the ratio of product costs to the augmentation of a characteristic product’s feature. Based on the results a definition for the characterization of large scale products is established referring to the technical, organizational and economical restraints and to the available processes and tools.
xxl-product, large-scale, xxl, definition
The range of structure sizes for industrial products produced today is increasingly expanding. This trend is evident in both small-scale (e.g. semiconductor applications) and large-scale (e.g. wind turbine rotors) products. While definitions already exist for smaller scale device structures, the conceptual distinction between conventional large products and large scale products is currently insufficient. In this study, we present a potential basis for the definition of large scale products. To achieve this, we derive hypotheses and examine these in the context of an empirical study using the examples of several sample products. It is shown that the transition from conventional products to large scale products is characterized by a disproportionate increase in product costs due to the augmentation of a characteristic product feature. Eventually we derive a proposed definition which characterizes large scale products in the field of production engineering.
xxl-product, large-scale, xxl, definition
Products have historically been subject to continuous development. On the one hand, these are to fix known issues and bugs compared to the original product. On the other hand, companies are forced by globalization to optimize their products globally in order to stay competitive in the market. Such development often involves not only a function of growth, but also needs a development of the geometric dimensions. For Example, the VW Golf has been added more and more safety and comfort features with each generation. In this way, the length of the VW Golf with every model change has increased by an average of 9cm.
xxl products, large-scale products, xxl definition
The systematic analysis of life cycle data provides the potential to identify weaknesses of current products and starting points for product innovations. This paper presents a tool for an automated analysis of life-cycle data and describes the necessary steps of a data analysis. In particular, the merging of data from different systems, the pre-processing of raw data, the data analysis and interpretation are explained. In this context, the pre-processing of free text is described. Moreover, two models for an automated analysis of life cycle data are introduced. Finally, the implementation of this concept into a software tool is described.
software tool, lifecycle, data analysis, data mining, knowledge deployment
An analysis of lifecycle data offers the potential to identify product weaknesses and starting points for product innovations. The paper describes a concept to analyze lifecycle data and declares which partial steps are necessary to collect, preprocess and analyze the data.
software tool, lifecycle, data analysis, data mining, knowledge deployment
The production of titanium parts in small batches using a flexible machine and a fast layout method as well as a temperature and defect measurement were not considered in investigations yet. However the industry using valuable materials showed interest in this technology and the CWR module in order to realize the advantages of the CWR technology for small and medium batch sizes. Therefore a CWR machine for flat wedge tools will be developed in the EU project CoVaForm. The wedge tools used in this project will be designed for rolling titanium and micro-alloyed steel. To help SMEs a software tool will be developed for designing CWR processes. Especially for rolling valuable materials like titanium, the boundary conditions are mostly unknown; therefore pre-tests will be done to get process parameters which will enable a working CWR process. To ensure a defect-free production, a quality control will be developed based on thermography which detects defective parts directly during the rolling operation.
cross wedge rolling, CWR machine, titanium, bainitic grade steel, common rail, hip implant
The production of titanium parts in small batches using a flexible machine and a fast layout method as well as a temperature and defect measurement were not considered in investigations yet. However the industry using valuable materials showed interest in this technology and the CWR module in order to realize the advantages of the CWR technology for small and medium batch sizes. Therefore a CWR machine for flat wedge tools will be developed in the EU project CoVaForm. The wedge tools used in this project will be designed for rolling titanium and micro-alloyed steel. To help SMEs a software tool will be developed for designing CWR processes. Especially for rolling valuable materials like titanium, the boundary conditions are mostly unknown; therefore pre-tests will be done to get process parameters which will enable a working CWR process. To ensure a fault-free production, a quality control will be developed based on thermography which detects faulty parts directly during the rolling operation.
cross wedge rolling, CWR machine, titanium, bainitic grade steel, common rail, hip implant
