The manufacturing principle synchronized individual production aims to balance variety and cost efficiency in production systems. It combines the process-orientation of a job-shop production and the flow-characteristic of a flow-shop production. A takt time is established and jobs are logistically allocated to takt pallets. German tool manufacturers are confronted with customers’ main demand to deliver tools on time. Especially synchronized production processes facing omnipresent disturbances are easily blocked or drained due to their nature of ideally excluding any laying and waiting periods. Consequently, the fundamental importance for production plans is thus to adapt effectively and efficiently to disturbances. Production control applies measures, but the lack of predictability of the production’s process of orders leads to longer, unreliable lead times. A high delivery reliability is thus based on a high schedule reliability and is the key to avoiding penalty costs by customers or any unnecessary production costs. This thesis aims for increasing the delivery reliability of a synchronized tool production by providing a proactive production-control strategy that improves adherence to delivery dates by establishing production-plan quality robustness with estimating disturbances, deriving necessary time buffers, and scheduling time buffers in the production plan proactively. Based on identified deficiencies, a concept for a proactive production-control strategy for a synchronized tool production is presented. The basic idea is to apply a proactive production control by estimating disturbance and deriving plus scheduling time buffers to prevent disturbances affecting the production plan of a synchronized tool production. The concept extends the production-control loop of a synchronized tool production: a disturbance estimator and a disturbance feedforward. The disturbance estimator convolutes disturbance functions to the aggregated takt-station level and derives an estimation about future disturbances. The disturbance feedforward transformed estimated disturbances in estimated time buffers and applied them in a proactive scheduling. By comparing cost of delay and of time buffers with algorithm of the thesis by Humphrey (2016), the proactive production-control strategy is validated. The results confirm the increase of adherence to delivery dates with a significant reduction in costs. The validation is demonstrated using an industrial application scenario.
Details
Autor Heutmann, Timo
Gewicht 0.255 kg
Erscheinungsdatum 03.08.2023
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Produktionsqualität und Messtechnik

Heutmann, Timo

Proactive Production Control for a Synchronized Tool Production

ISBN: 978-3-98555-164-4
Lieferzeit: 2-3 Tage
49,00 €
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Kurzbeschreibung

A synchronized tool production requires a high delivery reliability, which is based on a high production-plan reliability. This thesis develops a proactive production-control strategy that improves adherence to delivery dates by establishing production-plan quality robustness with estimating disturbances, deriving necessary time buffers, and proactively scheduling time buffers in the production plan. 

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