Simulation-based configuration of tools cycle in forging industry

Theme	Production planning
Project title	Simulation-based configuration of tools cycle in forging industry (SFB 489 C4)
Project duration	01.01.2010 – 31.12.2012
Download	Article in IPH's annual report 2010 (in German)

In forging and mold construction industry (FMC), small and medium-sized enterprises in single and small series production are heavily depending on its customers. They produce complex, capital-intensive goods, where the order is placed after a long bidding period and usually carried out with pre-defined and often very short-term delivery. Therefore, FMC are subject to substantial fluctuations in capacity utilization, where delivery reliability is crucial for obtaining further orders. According to that, a balanced planning and good control of production process is necessary. Regarding the 'dilemma of scheduling', the object of this research project is to develop a simulation-based method of forecasting of deliveries and validation of production control alternatives. Given requirements on simulation model are a low modeling effort as well as the operational use in practice.

Publications about the project

Tool- and Mold-Making Selaouti, A.: Simulationsgestützte werkzeugtypbezogene Konfiguration der Werkzeugversorgung am Beispiel von Schmiedegesenken. In: Behrens, B.-A.; Nyhuis, P.; Overmeyer, L. (Hrsg.): Berichte aus dem IPH, Band 3/2013, TEWISS – Technik und Wissen GmbH, Garbsen 2013.

Companies in which the typical tool cycle is used for their production tools and be found with reclamation and reuse are, seek to reduce the average delay deployment of ready tools. To improve the availability of production the number of tools in the circuit or the tool life of the tools can be increased. However, this in turn leads to higher cost. Thus, the achievement of an objective goes to the expense of another. The central part of the work presents the modeling of a typical tool cycle is in a simulation model. Thus, the basic relationship between the indicators and default provisioning tool inventory and their controllability by organizational and technological measures within the framework of simulation studies have shown.

tool allocation delay, tool logistics, tool stock, tool supply, material flow simulation

www.tewiss-verlag.de

Production planning Selaouti, A.; Baumgarten, S.; Nickel, R.: Effizienter Werkzeugeinsatz beim Präzisionsschmieden – Ein Ansatz für eine verbesserte Abstimmung zwischen Werkzeuginstandhaltung und Produktionsplanung und -steuerung. In: Industrie Management, Gito Verlag, 27. Jg. (2011), H. 6, S. 73-76.

On the one hand the precision forging involves substantial savings in material and process heat as well as in the reduction of the process steps. On the other hand, the tools are also much more exposed than the conventional forging. This leads to more rapid wear and a lower tool life of the tools. Within the framework of the subproject C4 of the Collaborative Research Center (SFB) 489 "process chain for the production of precision forged high performance components", therefore, a simulation-based approach will be developed, which allows the evaluation of new technical and organizational measures to improve the tool insert and thus supports a transfer into industrial practice.

precision forging, tool insert

Production planning Denkena, B.; Nickel, R.; Nyhuis, P.; Henjes, P.; Kennemann, M.; Selaouti, A.: Technologische und logistische Optimierung von Schmiedeprozessketten. In: ZWF, Carl Hanser Verlag München, 105. Jg. (2010), H. 12, S. 1069-1073.

The German forging industry is under ever increasing pressure to develop innovative products at low prices. The design of logistic efficient forging processes regarding economic aspects is an opportunity for cost reduction. Thereby, sumultaneous consideration of technological interfaces as well as indirect processes (e.g. tool logistics) leads to a continuous process chain optimization. Logistic effects of resulting process changes have to be identified within a dynamic production controlling system in order zu improve the logistic performance.

logistical optimization, process chain optimisation, production planning and -steering

Selaouti, A.; Knigge, J.; Nickel, R.: Simulative study of cause-effect interdependencies in tool logistics. In: Proceedings of International Conference on Advances in Mechanical Engineering 2010, Engineers Network-CPS, New York USA 2010, S.1-9.

Today, the forging industry is facing new challenges. The day-to-day business is characterized by fluctuating order quantities and the production of high numbers of variants. Under this condition the tool logistics is gaining more importance in order to minimize production downtimes through guaranteeing high tool availability with minimal tool costs. This paper presents an approach for a synchronisation of tool supply processes to production requirements by evaluation of the cause-effect interdependencies from tool life quantity and tool stock level on production performance and tool utilization.

forging industry, tool logistics, simulation study, cause-effect interdependencies, tool logistics o

Production planning Selaouti, A.; Nickel, R.; Nyhuis, P.; Bistron, M.; Behrens, B.-A.: Standmengenorientierte Losgrößenbestimmung in der Schmiedeindustrie. In: ZWF, Carl Hanser Verlag München, 105. Jg. (2010), H.4, S. 375-382.

This article presents research results concerning the wear behaviour of precision forging dies within the framework of the Collaborative Research Centre (CRC) 489 "Process chain for the manufacturing of precision forged high performance components". The wear behaviour is described in accordance to the wear curve of DIN 31051. Tests within the scope of this CRC have revealed two different kinds of measurable wear, material abrasion and material adhesion. Based on the wear curve of an examined precision forging tool the threshold level of damage is determined. The threshold level of damage complies with the maximal quantity of good parts which can be produced with the precision forging tool. An approach to identify an economic lot size for forging processes taking into account the maximal tool quantity was developed, in order to enable an integrated production planning and tool maintenance planning.

batch size determination, tool life quantity, abrasion behavior, forging industry

Production planning Selaouti, A.; Potthast, J.-M., Nickel, R.: Enhanced logistic reactivity in the Forging Industry. In: Logistics Journal: nicht-referierte Veröffentlichungen, o. Jg. (2010), DOI 10.2195/LJ_Not_Ref_Selaouti_Potthast_Nickel_062010.

Short term and frequent changes of delivery quantities and dates by customers as well as unreliable logistic behaviour of raw material suppliers cause logistic turbulences, which affect the accuracy of production planning and control (PPC). In order to assure more flexible reaction capability in combination with high level reliability of PPC, logistic risk management is essential, which enables an early identification, assessment and control of logistic risks in the supply chain. Within the research project "SFB 489 C4 - design and control of flexible supply chains for the production of precision forged components" a comprehensive approach was developed for the implementation of logistic risk management in PPC in flexible supply chains. This paper describes the developed methods for risk identification, risk assessment and risk control as well.

production planning and -steering, precision forging, tool insert, tool inventory reduction, forging