Smart factory - Module 1

Define production

transformative process, creates goods through combination of production factors

Draw the magic triagle of procuction, what does it signify

Cost, Quality and Time are the three obectives of production but achieving all of them at once is impossible — there must be a tradeoff

What is lead time

total amount of time between star of process and final completion of product

5 factors that contribute to complextities in production, explain each

• restrictions (laws, resource scarcity)

• quality requirements (tolerances, safety)

• market requirements (short product life cycle(more customers come back to buy again), fast production, fluctuating demands)

• coordination (globalization, just-in-time)

• variety (product variants, new materials)

What is just-in-time

Production and delivery operate accordingly to the demand of the next production unit with small batch sizes, materials ordered only as needed (no waste/overproduction)

Flexibity vs Adaptability

flexibility : reactive short term willingness to adjust to immediate minor changes, there are limits here, possible solutions are predefined

adaptability : proactive long term ability to change behavior/strategy

Areas in which production can be flexible

Process - make it easy to switch btw diff variants or batch size

Routing - disruption of one station in production should not put stop to all the production

Variants - brand new variants should be able to be produced with ease and quickly (e.g could be produced on same line, no need to change anything)

Volume - Production should be able to adapt itself to demand

Properties that make a production system adaptable (adaptability enablers)

Universatility - prod line built to accomodate to various products/ techs

Mobility - machinery should be able to be displaced freely

Scalability - tech, space and personnel volume should be flexible

Modularity - standardized, functional components (easy to switch out diff ones)

Compatibility - capability to connect everything as needed (standardized interfaces)

What are the two possible reaction in event of disruption in production line

Robustness or Resilience

Robustness vs Resilience

robustness : high and stable performance despite disruptions ( it is tolerated)

resilience : disruption dealt with by switching to new system state

What is lean management

focus on maximising productivity and customer value and minimising waste without sacrificing quality

define a bottleneck

slowest part of production process

Evaluating production systems from microeconomics perspective

how individual company can react to market conditions by adjusting internal strategy

(bottom up approach)

Evaluating production systems from macroeconomics perspective

see how political/economical global situation is affecting market conditions and see how this affects the individuals (buyers vs sellers)

(top down approach)

Basic principle of lean management

1 - 1 - 0

• 1 peice flow - minimal stocks, short lead time, better fault detection

• 100% added value - no waste, efficient production, maximised productivity

  • 0 errrors - error preventiton, high customer satifastion

what is IPS

Integrated Production System, it is a type of practical implementation of lean management, can be used as a guide for factories, the objectives are productivity, human centered design, and competitiveness

What are the 5 pillars of integrated production systems (IPS)

• Production/logistics

• Continuous improvement

• Standardization and Visualisation

• Quality and Stable processes

• Work organisation

in IPS what is the production/logistics pillar about

It is concerned with the flow of the production line

Design principles(guideline) of Production/logistics pillar in IPS

• Just-in-time

• 1 peice flow

• Pull production

Push vs Pull production system

Push : production operates indep. from demand of next stage in production chain (production decided by central planning authority)

Pull : production and delivery operate according to demand of next production stage ( procuction only starts when customers demands the product from end of supply chain)

1 piece flow

• layout of work station follows sequence of production processes

• continuous flow btw work stations

• no stock of semi finished goods

• no generation of waste

  • short set up times needed

What is set up

all activities between end of processing one product and start of processing of the next

Methods used in Production/logistics pillar in IPS

• reduction of set up times

• levelling of production times (production smoothing )

• Kanban

What is kanban

an inventory control system used in just-in-time (JIT), limits works in progress to promot continuous improvement. It is a visual system to prompt actions needed to keep a steady flow

Design principles(guideline) of continuous improvement pillar in IPS

• waste avoidance

• kaizen (find problem, analyse problem, find solution, implement solution, analyse solution, standardize solution if good and repeat)

in IPS what is the continuous improvement pillar about

improve continuously without major investments and with minor effort step by step

In which domains can waste avoidance be implemented

Transport

Inventory

Motion (have freely moving stations, arranged in ergonomic way)

Waiting (1 piece flow)

Overprocessing

Overproduction

Defects (rework instead of throwing away)

Method used in continuous improvement pillar in IPS, and relate to standardistion

PDCA — Plan , Do, Check, Act ( same as Kaizen ),, you need to standardise your solutions as you go so if something doesnt work in the future you know what to go back to

Design principles(guideline) of standardisation and visualisation pillar in IPS

standardisation : uniformisation of procedures and methods

visualisation : through info panels, boards and others, to provide better overview of objectives and production

Methods used in standardisation and visualisation pillar in IPS

• 5S

• standard worksheets

What are the 5S in standardisation and visualisation

guidelines for better transparency, quality, safety, through organisation and tidiness in production

• Tidiness

• Orderliness

• Cleanliness

• Personal sense of order

• Discipline

Design principles(guideline) of Quality and Stable processes pillar in IPS

• Preventive Quality Assurance

• TPM

• Six Sigma

Method used in Quality and Stable processes pillar in IPS

Poka-yoke: precautions taken to prevent errors or detect thel imediatly

what is TPM ( total productive maintenance)

aims to maximise OEE (overall equipment effectiveness) by minimising the 6 big losses

What are the 6 big losses in available time in production

• planned and unplanned stops (availability losses)

• slow cycles and small stops (performance losses)

• startup rejects and production rejects (quality losses)

without these we’re left with fully productive time ( value adding time)

How to calculate availability in production

How to calculate performance in production

How to calculate quality in production

How to calculate OEE (overall equipment effectiveness)

OEE= availabilty x qulity x performance

Design principles(guideline) of work organisation processes pillar in IPS

• Team Work

• Leadership

• Safe Workplace

• Employee

• Qualification

Method used in Quality and Stable processes pillar in IPS

• Training / Seminars

• On-the-Job Training

• Island of Learning (Training stations)

• Agreement on Objectives

What concept of production to use when the requirements become two complex for lean management

Smart Factory

What is smart factory

Fully integrated, collaborative manufacturing system that responds in real time to meet changing demands and conditions in the factory, in the supply network and in customer needs