- The IPH
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
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
Many small and medium enterprises (SMEs) miss their logistics objectives. In science and practice there is a growing recognition that the problems of production planning and control (PPC) cannot be solved only by the development and use of software tools. PPC systems usually have limited degrees of freedom for carrying out the tasks given to the employee. Many methods of PPC systems have the potential of influencing the behavior and performance of employees. The development of a logistics-oriented incentive system can support the logistical goal achievement of SME. Aligning incentives on operational logistics objectives anchors the objectives in the employees’ personal consciousness and everyday commitment the employees’ actions to support the logistics performance on the production level.
controlling, logsitic performance indicators, incentive system,
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
The continuous improvement of production processes is a requirement to achieve and secure competitive advantages. This includes, among other things, to develop differentiating features faster than the competitors. In addition to technological innovations, organizational and logistical processes offer a significant potential for cost savings to small and medium enterprises (SMEs). For this reason enterprise resource planning (ERP) systems are getting more and more important. This paper describes eight steps for selecting the optimal ERP system.
erp systems, erp selection
To survive in the rivalry of competing supply chains in strong market dynamics, logistic measures of single companies are no longer sufficient. The reaction to disturbances needs to be aligned within the supply chain. Otherwise losses of efficiency result as increased inventory costs and reduced logistic performance. These losses are caused in early tiers of the supply chain. Due to the Bullwhip effect, they result in highly amplified inefficiencies throughout the complete supply chain. This article presents the development of a methodical support for synchronising the logistic reaction in supply chains. Therefore, reactions on disruptions and demand changes are determined and – according to their effect on logistic objectives – quantified. Cause-effect relationships of all processes within the supply chain (Source, Make and Deliver) are identified.
supply chain management, logistic reactivity
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
Design and configuration of model-based rules. Disruptions in production with negative impact on the objectives of production logistics need to be identified and resolved. Small and medium sizes enterprises (SMEs) often lack of sufficient human capital to control the logistic relations in production and thus to realize a targeted improvement of a logistic process. Moreover, a profound knowledge about the complex relations between logistic objectives and measures against interferences in production is often missing. The missing knowledge of coherences may explain why aspired logistic objectives in SMEs are often not achied. This article introduces an approach for diagnosing interferences in production logistics and deriving recommendations for measures using an assistance system developed at the IPH - Institute of Integrated Production Hannover gGmbH.
assistence system, objectives of production logistics, diagnose of interruptions in production
A functional logistic strategy for production logistics may be deduced from a corporate strategy in order to ensure competitiveness. The challenge is to monitor the strategic guidelines by appropriate key data. When the monitoring identifies divergences, a diagnosis helps to derive measures at the operational level in order to ensure stable or improved processes. The paper introduces a rule-based expert system to help master these challenges. The approach is based on the production logistic objectives (low work in process level, short throughput time, high schedule reliability and high utilization) with their key indicators. In a problem solving tree, those key indicators are connected with further significant diagnostic key data, according to their cause-effect relationships. The expert system rules are based on the fundamental laws of production logistics by Wiendahl and Nyhuis. A diagnostic procedure for production logistics will be triggered by quality control charts in an expert system.
knowledge management in production and logistics, ict for manufacturing and logistics, intelligent,