Adaptive assembly of large-scale products

Theme
XXL products
Project title Adaptive assembly of large-scale products (Mont4XXL)
Project duration 01.03.2014 – 31.12.2015
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Press release
The assembly of large-scale products is generally organized as on-site assembly and is characterized by an insufficient availability of data, less standardized processes, high product variance and flexible resources. Assembling large-scale products involves frequent process interruptions induced by delayed material deliveries or missing availability of resources. This leads to a negative impact on the logistical performance of a producer of xxl-products. Therefore, the objective of research project is the development of a methodology which allows the identification, evaluation und visualization of process alternatives.
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  • 03.12.2015
  • IPH – Institut für Integrierte Produktion Hannover gGmbH, Hollerithallee 6, 30419 Hannover
  • 05.02.2015
  • ZPF GmbH, Petersäcker 4-6, 74936 Siegelsbach
  • 14.05.2014
  • WZL der RWTH Aachen, Steinbachstraße 18, 52074 Aachen
  • 14.05.2014
  • Jade Weser Port Info Center, Banter Deich 2, 26382 Wilhelmshaven

Publications about the project

Assembling large-scale products involves frequent process interruptions why in order to reduce the impact of interruptions, a short-term response is necessary to reduce delivery delays and idle times of resources. An approach to challenge this represents the flexibility of a production system. Regarding the environment of large-scale product assembly, it has to be shown which potentials of flexibility are able to be used in a short-term manner.

assembly, production management, disruption management

Assembling large-scale products, such as airplanes, locomotives, or wind turbines, involves frequent process interruptions induced by e.g. delayed material deliveries or missing availability of resources. This leads to a negative impact on the logistical performance of a producer of xxl-products. In industrial practice, in case of interruptions, the identification, evaluation and eventually the selection of an alternative order of assembly activities (‘assembly alternative’) leads to an enormous challenge, especially if an optimized logistical decision should be reached. Therefore, in this paper, an innovative, optimization model for the identification of assembly alternatives that addresses the given problem is presented. It describes make-to-order, large-scale product assembly processes as a resource constrained project scheduling (RCPS) problem which follows given restrictions in practice. For the evaluation of the assembly alternative, a cost-based definition of the logistical objectives (delivery reliability, inventory, make-span and workload) is presented.

assembly sequencing, logistical objectivs, optimization modell

Assembling large-scale products involves frequent process interruptions. To reduce the duration of an assembly stop, the WZL of RWTH Aachen University and the IPH Hannover developed an approach which is able to identify alternative assembly plans and to evaluate them on the basis of the logistic performance objectives. Stock, capacity utilization, lead time and adherence to schedule are transferred into costs and assembly plans are thus comparable based on one parameter.

production planning and control, assembly, logistical objectives

Assembling large-scale products involves frequent process interruptions induced by e.g. delayed material deliveries or missing availability of resources. Our approach for identifying alternative assembly sequences by analyzing the product structure and process dependencies allows for continuing with the assembly process in case of interruptions and therefore increases the process efficiency.

large-scale product, adaptive assembly, alternative assembly process

The assembly of complex, large-scale products is often characterized by poor date availability, limited process standardization, frequent product modifications and flexible usage of resources, which often leads to interruptions in the assembling process. Therefore, in a research project between the IPH Hannover and the WZL of RWTH Aachen University, a methodology for assembly processes is developed which allows the identification and evaluation of process alternatives in case of interruptions. For the evaluation of those process alternatives logistical objectives are used.

xxl-product, adaptive assembly scheduling, interruption assembly process, logistical objectives

Sponsor

The IGF project 17707 N of the research association BVL was funded via the German Federation of Industrial Research Associations (AiF) in the programme of Industrial Collective Research (IGF) by the Federal Ministry for Economic Affairs and Energy (BMWi) based on a decision of the German Bundestag.

Partner

Your contact person

Henrik Prinzhorn
M.Sc.

Project engineer

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