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
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,
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
Up to the present day, literature has already dealt with stockout-costs, but methods to quantify these costs have not been developed until now. The absence of these kinds of methods prevents an efficient logistic positioning between stockout-costs and the costs for holding safety-stocks. The costs for safety-stocks in a warehouse to provide a desired service-level can already be determined, but the stockout-costs connected with a desired service-level cannot be quantified yet. This article introduces a mathematical function to quantify the costs in a company’s production caused by missing material, depending on the amount of missing material and its missing time.
stockout costs, material shortage, service-level, logistic costs, warehouse costs
The increasing demands customers are placing force companies to cooperate closely in supply chains in order to ensure a high logistic performance. The customers’ demands also enhance the shortening of product life cycles which cause more frequent phase-outs of products and components in supply chains. Therefore today’s supply chains must be able to conduct phase-outs efficiently. This paper presents a suitable approach for a systematic phase-out planning taking the whole supply chain into consideration. The approach is based on the cumulative production figure principle which allows the linkage of supply chain processes. It supports an alignment of the lot sizes of the processes source, make and deliver to the phase-out production volume. The approach enables supply chain partners to identify possible cost reductions in terms of avoiding remaining stock due to nonharmonized lot sizes.
factory and production planning, networking in international production/manufacturing and logistic n
This article describes the logistic challenges of producing in networks. Followed by a definition of a production network, the greatest chances as well as the potential risks of producing in networks are identified. The unique features and requirements of network production in comparison with single enterprise production are pointed out and the production logistic research need is derived.
production, production networks, logistics, xxl-products
An efficient logistic controlling conducting a diagnostic of production logistic with a rule-based expert system can assist companies and in particular small and medium sized enterprises to meet the increasing requirements of the market concerning logistic efficiency. These requirements must, however, be aligned with the company's strategy. Based on the company's strategy a functional strategy has to be derived for the company's logistic to put the superior objectives sustainably into practice. The challenges are the derivation and monitoring of appropriate logistical key indicators that represent the strategic goals, in diagnosing a dysfunction in the production logistic as well as in the derivation of appropriate operational measures to handle the dysfunction and thereby to support the strategy.
logistical controlling, sme, keyindicators
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
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
