Applied Mechanics and Materials Vol. 794

Abstract: This optimisation approach focuses on the shop floor of a manufacturing company. It aims for an integrated lean and green assessment of a manufacturing system and the identification of a cost optimized combination of lean and green strategies with regard to green targets. For green assessment material and energy inputs as well as resulting CO₂ emissions are taken into account. Lean assessment focuses on costs and throughput time. Potential lean and green strategies identified during top down analysis are integrated into a discrete event simulation model. This model is connected with optimisation heuristics which improve combined lean and green strategy deployment to the manufacturing system.

Abstract: Cybertronic systems which augment mechatronic basis systems by means of communication, collaboration and intelligence are proposed to be utilised to develop next generation production systems. A model-based development process is proposed to enable integrated design and development of the product and the production system. This paper will highlight the importance of process planning as collaborative activity within the integrated design and development process. A concept will be introduced how process planning can be conducted for cybertronic production systems, considering decentralised production planning and control already during the design phase.

Abstract: In this paper, an approach to quantify the effects of disruptions in a complex job shop manufacturing is introduced. Key figures within this approach are the effects of disruptions on logistic targets. With the help of discrete event simulation, the consequences of several disruptions are quantified and visualized.

Abstract: Concurrent Engineering has been accepted as an integrated development concept offering significant benefits regarding to cost and development time. Despite of this agreement and the fact that shortened product lifecycles increase the necessity for stronger interaction between all stakeholders involved in product development, benefits are not achieved to the predicted extend. While reasons are manifold, a lack in structured and efficient communication between different departments can be identified as a key obstacle. Recent research activities had addressed requirements management processes outside the limited domain of software and product development and allowed for an integration of production requirements. This paper presents an approach which allows for a continuous requirements process within the production departments. Thus ensuring the integration of up-to-date requirements in all development activities.

Abstract: Efficient operation and maintenance processes are important factors to reduce the operating costs of industrial facilities and components. Therefore, both research and industry developed maintenance strategies ranging from fixed time intervals to condition-based activities. However, due to unpredictable events, disturbances and unknown processing times for maintenance activities, many strategies do not meet the requirements of real-world industrial systems. In this paper, a new data-driven concept is presented where data analysis is used to support the dynamic adjustments of maintenance intervals. An overall strategy is developed in which the analysis of data is an integral part for standard maintenance processes, considering their particular workflow and their constraints. The analysed data come from different systems such as Enterprise Resource Planning, Condition Monitoring Systems, and internal service logs of the components or from maintenance activities. The concept encompasses the aligned application of different methods for aggregating these data and for predicting the component’s condition and its remaining useful life. In particular, it is exemplarily shown how the Weibull distribution, the Wiener process, and neural networks are combined to support decisions regarding the dynamic adjustment of the maintenance intervals in industrial facilities. This leads to a better utilisation of components, avoids failures and breakdowns and saves cost. The capability and applicability of these methods is illustrated by applying them to generators of an offshore wind farm.

Abstract: Manufacturing enterprises are currently competing in an environment characterised by shortening product life cycles, an increasing diversity of variants, and an ever-evolving globalisation. The resulting dynamism leads to steadily increasing expectations regarding the logistical performance which have to be met by enterprises in order to remain successful in the market. In this context, schedule reliability is of crucial importance. At the same time, diversity and complexity of value-added processes obscure the interdependency of logistical objectives and the possibilities of influencing them. This is where logistical models help to still describe the correlations. Such a logistical model is developed in this paper. It contributes to calculate the lateness distribution and, thus, the schedule reliability along linear and converging material flows.

Abstract: Rising cost pressure and the trend of extensive product customization lead to a situation in which the management of interfaces between different areas of process chains is a substantial strategic success factor. Since tooling is commonly placed as an element on the critical path between product development and serial production, the design and management of this interface has a significant impact on the key factors time-to-market, quality and costs. Based on the presented motivation, this paper provides a methodology to estimate the effects of product design decisions on the necessary tools regarding time, quality and costs. It is based on a systematic approach for the interaction of product and tool parameters and focuses on the effect and handling of external restrictions on product features.

Abstract: Many companies are exposed to the challenge to fulfill constantly growing heterogeneous costumer requirements and simultaneously deliver the highest quality standards for their products. One way to face these challenges is the highly iterative product development approach. The content of this approach is the division of the current development process in many short and iterative sub processes (sprints). This procedure enables a regular involvement of the customer in the development process and an early validation of the development status which jointly results in costumer-specific and marketable products. As a consequence of this short-cycled approach the requirements for the practiced process of development projects change fundamentally. However, most companies do not know how this new short-cycle development process has to look like for their daily project work. This is due to the fact that most published papers just deal with the description of how the highly iterative methods look like, however, without considering the challenges an implementation in a producing company involves. This paper aims at the presentation of a standard approach for the handling of highly iterative product development projects.

Abstract: New and innovative products are drivers for successful and sustainable growth of companies. Only a continuous stream of innovations can defend established market segments and create new markets for the company. Especially for European companies, innovations offer the opportunity for differentiation against competitors and therewith help to consist the present cost pressure mainly coming from Asian countries. Thereby, innovation inherent risks regarding limited product success, longer development times and quality lacks threaten the success of the innovation process. With this paper, a new approach is introduced, which aims at the reduction of the risks in the innovation processes. This is realized by shifting the focus from a customer requirement driven innovation screening to a product portfolio based innovation approach. The idea is to identify innovation opportunities within existing portfolios to maximize the use of existing company capabilities.

Abstract: For the application of Additive Manufacturing (AM), a wide range of use cases are applied in industrial practice. The technological potentials of AM enable specific business models, which characterise how AM utilisation adds value to a company’s business. For the implementation of AM, a paradigm shift is required on an operational and strategic level, making it necessary to adjust processes and structures. Herein, the interdisciplinary character of the technology needs to be taken into account. In this paper, a typology of AM business models is derived from specific technology potentials, providing orientation in the field of AM use cases. Furthermore, a top down approach is pursued in order to develop an implementation process model, which assists companies when considering AM adoption. It enables companies to identify suitable AM business models and points out fields of actions necessary for implementation. Since the implementation depends on the AM business model at scope, also guidelines that provide measures on a more detailed level are presented.