Table Of ContentFlexibility Measurement in Production Systems
.
Sven Rogalski
Flexibility Measurement in
Production Systems
Handling Uncertainties in Industrial
Production
SvenRogalski
FZIForschungszentrumInformatik
Universita¨tKarlsruhe
Haid-und-Neu-Str.10-14
76131Karslruhe
Germany
[email protected]
ISBN978-3-642-18116-0 e-ISBN978-3-642-18117-7
DOI10.1007/978-3-642-18117-7
SpringerHeidelbergDordrechtLondonNewYork
LibraryofCongressControlNumber:2011925658
# Springer-VerlagBerlinHeidelberg2011
Thisworkissubjecttocopyright.Allrightsarereserved,whetherthewholeorpartofthematerialis
concerned,specificallytherightsoftranslation,reprinting,reuseofillustrations,recitation,broadcasting,
reproductiononmicrofilmorinanyotherway,andstorageindatabanks.Duplicationofthispublication
orpartsthereofispermittedonlyundertheprovisionsoftheGermanCopyrightLawofSeptember9,
1965,initscurrentversion,andpermissionforusemustalwaysbeobtainedfromSpringer.Violations
areliabletoprosecutionundertheGermanCopyrightLaw.
Theuseofgeneraldescriptivenames,registerednames,trademarks,etc.inthispublicationdoesnotimply,
evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevantprotective
lawsandregulationsandthereforefreeforgeneraluse.
Coverdesign:WMXDesignGmbH,Heidelberg,Germany
Printedonacid-freepaper
SpringerispartofSpringerScience+BusinessMedia(www.springer.com)
Author’s Note
In order to keep up in a constantly changing and evolving world, it is important
to adapt to new demand swiftly. Dinosaurs dominated the earth for a long time
until their sluggishness and inability to adapt to the changing climate led to their
extinction. Other animals managed to sustain the various climate changes and
followedthetidesofevolution.Eventually,itwasmankindthatprevailedoverall
other life forms with its cognitive, affective, and social abilities, ruling the earth
until today. The same basic principle applies to the business world where, in the
longrun,companiescanonlypersistiftheypermanentlyevolveandreactflexibly
to changing environmental influences. For manufacturing firms especially, this
means that they need to plan their resources in a way that permits them to stay
costanddemandefficienteffectively.Intimesofveryhighcustomerindividualiza-
tionandavastvarietyofproductsandmodels,evershorterproductlifecyclesand
frequent technological innovations, companies must find the right answers to the
following crucial production related questions in order to persist on the global
market:
l Howcanfrequentlychangingcustomerrequirementsbeanalyzedandmet?
l How can production systems be developed efficiently and reconditioned
sustainably?
l How to make customized high-quality products within a tight budget and time
frame?
Computer integrated manufacturing, virtualcompanies and integral production
concepts are no longer enough to master the increased challenges of improving
productionflexibility,whichareexacerbatedbythecurrenteconomiccrisis.What
is, in fact, needed is a holistic analysis of technical and organizational degrees of
freedom in production. In this context, production managers are looking for new
methodsandtoolstohelpplan,monitorandadapttheirproductionsystems,which
include product life cycle and system related aspects in their aim for operating
efficiency.
SvenRogalski
v
.
Contents
1 Introduction ................................................................ 1
1.1 ImportanceofFlexibilityinProduction ................................ 1
1.2 CurrentTrendsinHandlingFlexibilityintheField ................... 3
1.3 ObjectiveofThisBook ................................................. 6
2 AnalysisoftheFieldofObservation ...................................... 9
2.1 ProductionSystems ..................................................... 9
2.1.1 DefinitionofTerms ............................................... 9
2.1.2 ResourcesofaProductionSystem ............................. 11
2.1.3 ObservationLevelsinProductionSystems .................... 15
2.1.4 ChangeDriversandAdaptationObjectsof
ProductionSystems ............................................. 21
2.2 FlexibilityofProductionSystems ..................................... 23
2.2.1 ApplicationofTermsandDimensionsofFlexibility .......... 24
2.2.2 ClassificationofFlexibility ..................................... 27
2.2.3 RelevantCriteriaforFlexibilityEvaluationonProduction
Systems ......................................................... 30
2.3 AnalysisofRelevantEvaluationMethodologiesforMeasuring
FlexibilityofProductionSystems ..................................... 31
2.3.1 EvaluationMethodologybyZa¨handMu¨ller ................... 32
2.3.2 EvaluationMethodologyPLANTCALCTM .................... 33
2.3.3 EvaluationMethodologybyWahab,WuundLee ............. 34
2.3.4 EvaluationMethodologybySchuh,Gulden,Wernho¨ner
andKampker .................................................... 34
2.3.5 EvaluationMethodologybyAliandSeifoddini ............... 35
2.3.6 EvaluationMethodologyDesyma .............................. 36
2.3.7 EvaluationMethodologybyPela´ez-Ibarrondo
undRuiz-Mercader ............................................. 37
2.3.8 EvaluationMethodologyPenaltyofChange .................. 37
2.3.9 EvaluationMethodologybyHaller ........................... 38
2.3.10 EvaluationMethodologyFLEXIMAC ........................ 39
2.4 NeedforaNewMethodologyandRequirements ..................... 40
vii
viii Contents
2.5 RequirementsforaNewEvaluationMethodology ................... 42
2.5.1 FundamentalApplicability ..................................... 43
2.5.2 FlexibilityMetrics .............................................. 44
2.5.3 ProductionSystemModel ...................................... 45
2.5.4 SoftwareImplementation ....................................... 46
3 IntroductionofaNewEvaluationMethodology ........................ 47
3.1 FundamentalApproachfortheEvaluationofVolume-,
Mix-andExpansionFlexibility ....................................... 47
3.1.1 EvaluationProposalforVolumeFlexibility ................... 48
3.1.2 ApproachtoEvaluationoftheMixFlexibility ................ 49
3.1.3 EvaluationApproachtoExpansionFlexibility ................. 50
3.1.4 ComparativeConsiderationandGeneralConditions
oftheEvaluation ................................................ 52
3.2 CalculationProcedurefortheMeasurementofFlexibility ........... 55
3.2.1 BaseAlgorithm ................................................. 55
3.2.2 FlexibilityEvaluationMethodofVolumeflexibility .......... 68
3.2.3 FlexibilityEvaluationMethodofMixFlexibility .............. 79
3.2.4 FlexibilityEvaluationMethodology
ofExpansionFlexibility ........................................ 85
3.3 DefinitionoftheCostAccountingReferenceFrame ................. 89
3.3.1 ChoiceofaCostAccountingProcedure ....................... 89
3.3.2 DeterminingtheHierarchiesofReference ..................... 91
3.3.3 DefinitionofBasicCostTypes ................................. 92
3.3.4 ClassificationofDefinedCostTypesinCostCategories ..... 101
3.4 ConceptoftheProductionSystemModel ............................ 105
3.4.1 TheObject-OrientatedReferenceModel ...................... 105
3.4.2 ThePrincipleofInheritanceoftheReferenceModel ......... 106
4 PracticalExperienceintheNewMethodology ........................ 109
4.1 ImplementationoftheEvaluationMethodology ..................... 109
4.1.1 SoftwareArchitectureofecoFLEX ........................... 109
4.1.2 ImplementationofecoFLEX ................................. 112
4.1.3 FunctionalityofecoFLEX ..................................... 114
4.2 CaseStudy-RelatedApplicationExperience ......................... 118
4.2.1 InitialSituationattheCompany ............................... 119
4.2.2 ObjectAreaoftheCaseStudy ................................ 119
4.2.3 ApplicationoftheEvaluationMethodology
intheContextoftheCaseStudy .............................. 122
4.3 RequirementRelatedAssessmentoftheEvaluationMethodology .. 129
4.3.1 VerificationoftheSoftwareImplementation ................. 130
4.3.2 VerificationoftheProductionSystemModel ................. 131
4.3.3 VerificationofFlexibilityMetrics ............................. 133
4.3.4 VerificationoftheFundamentalApplicability ................ 135
Contents ix
5 SummaryandOutlook ................................................... 141
5.1 Summary .............................................................. 141
5.2 Outlook ............................................................... 146
6 Appendices ................................................................ 149
6.1 BasicKnowledge ..................................................... 149
6.1.1 MethodsofCostAccounting .................................. 149
6.1.2 TheSimplex-Algorithm ....................................... 157
6.1.3 ObjectOrientation ............................................. 159
6.2 AdditionalMethodsforCalculatingofFlexibility ................... 163
6.3 DemonstrationofFurtherAspectsRegarding
theEvaluationMethodology ......................................... 165
6.3.1 CalculationofEnergyCostsforWorkplaces ................. 166
6.3.2 ProcessTimeasPartoftheCycleTime ...................... 167
6.4 ExampleofaProductionSystem(forIllustrating
FlexibilityCalculations) .............................................. 168
6.4.1 GraphicalStructureandTerms ................................ 168
6.4.2 CalculatingParametersoftheSystem ......................... 169
6.4.3 ExpansionAlternativesforSegmentS2 ....................... 170
6.5 CalculationParametersoftheExpansionActivities
fromtheExampleProductionSystem ................................ 172
References .................................................................... 175
Index .......................................................................... 185
