Abstract: As a reaction to current challenges in factory planning, many companies think about introducing factory standards to lower planning times and decrease planning costs. If these factory standards are set-up with a high level of modularity, they are defined as modular factory systems. This paper deals with the main current problems in the application of modular factory systems in practice and presents a solution approach with its basic models. The methodology is based on methods from factory planning but also uses the tools of other disciplines like product development or technology management to deal with the high complexity, which the development of modular factory systems implies. The four basic models that such a methodology has to contain are introduced and pointed out.
Abstract: Due to shortening product and technology lifecycles, many companies use standardization approaches in product development and factory planning to reduce costs and time to market. Unlike large companies, where modular systems are already widely used, small and medium-sized companies often show a much lower degree of standardization due to lower scale effects and missing capacities for the development of these standards. To overcome these challenges, the development of industry sector specific standards in cooperations or by third parties is an interesting approach. This paper analyzes which branches that are mainly dominated by small or medium-sized companies might be especially interesting for the development of factory standards using the example of the German industry. For this, a key performance indicator based approach was developed that will be presented in detail with its specific results for the German industry structure.
Abstract: In the current economic climate, for many businesses it is generally no longer sufficient to pursue exclusively economic interests. Instead, integrating ecological and social goals into the corporate targets is becoming ever more important. However, the holistic integration of these new goals is missing from current factory planning approaches. This article describes the conceptual framework for a planning methodology for sustainable factories. To this end, the description of the key areas for action is followed by a description of the principal components for the systematization of sustainability for factories and their stakeholders. Finally, a conceptual framework is presented which integrates the components formulated into an established factory planning procedure.
Abstract: In order to remain competitive in what is a turbulent
environment; businesses must be able to react rapidly to change. The
past response to volatile market conditions was to introduce an
element of flexibility to production. Nowadays, what is often
required is a redesign of factory structures in order to cope with the
state of constant flux. The Institute of Production Systems and
Logistics is currently developing a descriptive and causal model for
the redesign of plant structures as part of an ongoing research project.
This article presents the first research findings attained in devising
this model.
Abstract: The building of a factory can be a strategic investment
owing to its long service life. An evaluation that only focuses, for
example, on payments for the building, the technical equipment of
the factory, and the personnel for the enterprise is – considering the
complexity of the system factory – not sufficient for this long-term
view. The success of an investment is secured, among other things,
by the attainment of nonmonetary goals, too, like transformability.
Such aspects are not considered in traditional investment calculations
like the net present value method. This paper closes this gap with the
enhanced economic evaluation (EWR) for factory planning. The
procedure and the first results of an application in a project are
presented.
Abstract: Manufacturing companies are facing a broad variety
of challenges caused by a dynamic production environment. To
succeed in such an environment, it is crucial to minimize the loss of
time required to trigger the adaptation process of a company-s
production structures. This paper presents an approach for the
continuous monitoring of production structures by neurologic
principles. It enhances classical monitoring concepts, which are
principally focused on reactive strategies, and enables companies to
act proactively. Thereby, strategic aspects regarding the
harmonization of certain life cycles are integrated into the decision
making process for triggering the reconfiguration process of the
production structure.
Abstract: Due to short product life cycles, increasing variety of
products and short cycles of leap innovations manufacturing
companies have to increase the flexibility of factory structures.
Flexibility of factory structures is based on defined factory planning
processes in which product, process and resource data of various
partial domains have to be considered. Thus factory planning
processes can be characterized as iterative, interdisciplinary and
participative processes [1]. To support interdisciplinary and
participative character of planning processes, a federative factory
data management (FFDM) as a holistic solution will be described.
FFDM is already implemented in form of a prototype. The interim
results of the development of FFDM will be shown in this paper. The
principles are the extracting of product, process and resource data
from documents of various partial domains providing as web services
on a server. The described data can be requested by the factory
planner by using a FFDM-browser.
Abstract: In today-s turbulent environment, companies are faced with two principal challenges. On the one hand, it is necessary to produce ever more cost-effectively to remain competitive. On the other hand, factories need to be transformable in order to manage unpredictable changes in the corporate environment. To deal with these different challenges, companies use the philosophy of lean production in the first case, in the second case the philosophy of transformability. To a certain extent these two approaches follow different directions. This can cause conflicts when designing factories. Therefore, the Institute of Production Systems and Logistics (IFA) of the Leibniz University of Hanover has developed a procedure to allow companies to evaluate and design their factories with respect to the requirements of both philosophies.