Forging companies are often suppliers of the automotive industry, which has, by the implemented principles of Just-In-Time production, particularly high demands on the logistics performance of their suppliers. Moreover, the cost pressure in this industry is very high, so forging companies are striving to minimize their logistics costs. One of the factors influencing these logistics costs is the amount tools in a company’s tool inventory. Since the tooling costs have a high percentage of the product costs, strategic positioning between logistics performance and costs in the forging industry holds great potential. However, while a too low number of tools may cause delays in production and more frequent setting-ups caused by division of production lots and a concomitant increase of setting-up times of up to 30%, a possible consequence of too high tool inventories is the increase of process uncertainty by a prolonged and more stray tool circuit pass-through time. A structured approach to the positioning of the tool supply between logistics performance and costs is presented.
production planning and -steering, production management, tool inventory reduction, servicelevel, fo
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
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
Increasingly demanding markets and reduced production depths force manufacturers of complex products to better coordinate supply processes for assembly. In this article a research project is presented which aims to develop a control procedure for companies to react on delivery date deviations in supply processes. Particularly, as companies act as part of a network, a reasonable behavior in that perspective is sought.
company networks, simulation, supply processes, supply chain management, cooperation
The industrial production process is subjected to a high coordination and communication needs arising from the division of labor as a result of specialization. Trade-offs are omnipresent. For decision making the used indicators often do not have the same information base. The information-based reorganization of tasks can help here. The aim is to increase the decision quality and speed.
task allocation, information needs, organizational design, production indicators
Manufacturing companies are forced to reduce their energy costs because of rising electricity tariffs. Due to the increasing volatility of energy rates so far unused potential arises. As a sub-discipline of production planning and control the manufacturing control determines the temporal process of work orders and has great impact on the energy costs of the production. This article describes the approach of an energy cost-efficient manufacturing control, taking account of the established targets.
time-varying energy costs, fluctuating energy consumption, manufacturing control, production plannin
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 growing dynamics in the economic environment necessitate new approaches for analyzing and influencing the dynamic behavior of production networks. Analysis of nonlinear dynamics can help to differentiate the causes of the formation of dynamics. One key cause is the production network partners’ differing responsiveness, i.e. the logistics capability to react.
supply chain design, logistics reactivity, peripheral production network, dynamic systems
The energy costs‘s share in the total is increasing in producing companies. Due to variations in the energy consumption over the day, arising power peaks lead to high energy costs. Power peaks could be reduced by load management systems. But these systems could have a negative impact on logistic performance figures. A simultaneous optimization of logistic performance figures and the energy consumption is not available yet. In this article a method for the energy cost-based production scheduling is presented. This method schedules jobs on machines in a way that the energy consumption is equalized and the logistic performance (makespan, stock, job delays, workload) is ensured.
energy costs, power peaks, production scheduling
Manufacturing companies of xxl products are increasingly forced to distinguish themselves from their competitors by the production costs. Commonly used manufacturing principles are designed for a customized production with high product variety. However, with regard to the production costs these manufacturing principles are insufficient. The transfer of alternative manufacturing principles to the xxl production offers a promising approach to increase the productivity.
flow-production, xxl goods, reorganization, manufacturing principles, prefabrication
Stocks enable a defined service degree even at varying demands. Shortterm changes of the demand behavior can, however, cause missing part situations. In case the production is able to adapt the amount of production to a changed demand situation at short notice, the delivering ability can remain unchanged. At stochastic demands the right time of the change of amounts of production is a central question.
production quantities fluctuating demands, degree of service, delivery capability
Economic environments that are becoming more and more turbulent demand a rising schedule and quantity flexibility from companies. To achieve simultaneously a high economic efficiency a high amount of load flexibility on the shop floor is required. By which factors the existing amount of load flexibility in a production is influenced and how it can be measured is not answered yet. To bridge this gap an actual research project aims towards developing a method to quantify load flexibility in a production.
work load flexibility, work load smoothing, work load scattering, production control method, product
The design of the delivery concept represents a decisive competitive factor for companies, since this significantly affects the throughput time and inventory levels. This paper explains how environmental issues can be quantified in addition to the conventional types of costs and presents a method for the selection and design of a delivery concept.
ecological costs, delivery concepts, logistics costs, procurement
This paper discusses the influence of circadian performance fluctuations on workers conducting manual assembly tasks under consideration of biorhythm. A data analysis method statistically verifies the correlations between performance fluctuations and investigated biorhythm. Finally, the paper suggests different areas of practical application of the confirmed performance fluctuations (e.g. shift work, cycle time adjustment).
performance efficiency fluctuation, assembly, industrial work system, data analysis method
The performance in logistics is vitally important for Companies. However the achievement of logistics objectives is deflating in practice. A possible reason are divergent employee and company interests, which constrict an efficient order processing. Once more employees are in focus in research and practice. How to resolve these differences in employee and company interests to enhance logistics? The Incentive System which is developed by IFA and IPH in Hannover provides solutions for an effective support of logistic objectives.
incentive system, logistics, divergent employee and company interests
Against the background of growing dynamics in the economic environment, new approaches to analyze and influence the dynamic behavior in production networks need to be found. The analysis of nonlinear dynamics can help to differentiate causes of the formation dynamics. A significant cause is the different logistic reactivity of the supply chain partners.
dynamic, production network, supply chain, supply chain management
In the past, scientific analysis of development and production of large-scale products has not been conducted very often. In the joint project „Innovations for the production of large-scale products“, sponsered by two German ministries in the state of lower saxony, IPH – Institut für Integrierte Produktion Hannover gemeinnützige GmbH will make a contribution to reply scientific questions in consideration of development, production and recycling of large-scale products.
xxl-products, development, manufacturing, recycling
To improve its production and reduce inventories, the mechanical and plant engineering company "Koller" is currently conducting a new software. Without the hardware, the actual investment is 350,000 EUR in total.
lean production, erp systems
Manufacturing companies are now more than ever surrounded by a turbulent market environment. At the same time, the importance of networks and value-added networks. In theory and practice over and above the classical flexibility beyond mutability is seen as a precondition to be able to survive in this environment. Unfortunately, many companies are contrary to a number of technological and organizational change barriers in achieving versatile factory and network structures. This article gives an overview of the state of research and the development needs of the mutability of supply chains. In addition, requirements and potential solutions are presented, by what technologies and methods in the future the versatility can be improved and conversion barriers can be dismantled. The conversion-design of transport, storage and IT systems as well as planning and evaluation of the adaptability in supply chains are described mainly.
mutability, supply, factory and network structures, technological and organizational change barriers
Due to converting material flow in assembly areas inadequacies in logistics often lead to disturbances, bottlenecks and adaptation costs. In this contribution an approach is introduced, which systematizes the time-dynamic description of all processes for the assembly regarding relevant logistic and monetary targets. In this way it contributes to a comprehensive process and system understanding.
production planning and -steering, assembly throughput diagram, assembly controlling
