Industrial Excellence KPP319 Product and Process Development Mats Jackson, mats.jackson@mdh.se Magnus Wiktorsson, magnus.wiktorsson@mdh.se
Course objectives The aim of the course is to give the student a deeper knowledge within the context of "Industrial Excellence" and "Competitive Production Systems", how to apply knowledge and model, simulate and analyse industrial processes. The objective is to learn and get experience from an industrial analysis based on the concept of modeling, simulation, animation and analysis. The means in the course is to perform an simulationbased study of an industrial production process, complemented by advanced production system analysis methods, current process and suggested improvements. In a program context of Optimization Problem analysis Simulation
Learning objectives After the course, the student should: show ability to critically and systematically integrate knowledge and to make models, simulate, predict and evaluate courses of events, also at limited information show ability to develop and design processes and systems with consideration to sustainable development and peoples conditions and needs A complement to another course - WER043 Extend Sim
Course objectives Project Production system analysis - discrete event simulation is to be used for modeling, simulation and analysis of manufacturing process Classroom lectures, seminars and simulation exercises Understanding and application in a project Individual reflection (PM) 5 pages due 2012-10-16
Course background and motivation Competing through operations Competitive production systems and its ideas, methodologies and tools. Production process development, analysis of processes and methodology for rationalization studies. Methods for and introduction of lean production in modern production systems. Modeling and simulation as tools with focus on discrete event controlled simulation. Design and evaluation of production systems
Course plan Examination INL1, 3 credits, PM - literature study INL2, 3 credits, Project report. Marks are set based on results from both project work and project report SEM1, 1.5 credits, Seminar and exercise of simulation Grades 3, 4 or 5 Literature Krajewski & Ritzman Operations Management. Pearson Selected Journal and conference papers
Teaching methods The teaching will essentially include lectures, seminars and literature review The course presupposes continuous participation, the students own studies and initiative and that all parts of the course are fulfilled within the time schedule of the course. The participants perform themselves a literature review A group project with 3 persons
Individual literature study An individual reflection on future development regarding simulation as a tool within production and logistics management. In a brief PM (max 5 p), reflect and discuss upon following key topics for the future of discrete event simulation: 1. Model size and complexity, future trends 2. Verification and validation techniques 3. Optimization using simulation 4. Parallel and distributed simulation 5. Internet based simulation 6. Human behavior and uncertainty modeling and simulation 7. Possible integration with ERP, PLM etc. Search and refer to sources by your self! PM physical hand in and presentation 2012-10-16 Max 5 pages reflections and discussion.
Project The participants perform in a group of 3 persons a project. A simulationbased study of an industrial production process, complemented by advanced production system analysis methods. A production system analysis focusing an aspects of industrial excellence Develop a logic model as well as a visualized model of the object that is analyzed Simulation using Extend Sim and Visual Components Valid and relevant modeling and analysis to the objective of study. Expected results: Simulation model and analysis Project report hand in 2012-12-04 Group presentation 2012-12-11 and 2012-12-18
Projects Examples on possible projects are: 1. GKN Driveline Köping (f.d. GETRAG) Projekt Fosfatering: Bakgrund: Fosfatering är en ytbehandlingsprocess som vissa av våra produkter går igenom. Kapaciteten i anläggningen har hittills inte varit något problem. Men för att vi ska kunna möta det framtida kundbehovet måste anläggningen optimeras och kapaciteten höjas. Mål: Se över fosfateringsprocessen och komma med förslag på hur vi kan styra materialflödet för att höja kapaciteten i anläggningen. Syfte: Höja kapaciteten i anläggningen för att möte framtida kundbehovet. Projekt Kulpening: Bakgrund: Kulpening är en operation som utförs av ett externt företag som ligger i anslutning till vår fabrik. Materialflödet till och från kulpeningen är inte definierat och inte styrd. Detta bidrar till att vi inte får tillbaka rätt variant i rätt tid i rätt mängd. Mål: Se över flödet till och från kulpening och komma med förslag på hur vi kan styra och dimensionera detta flödet Syfte: Få ett flöde till och från kulpening som är tydlig och väl definierad som underlättar för operatörerna att ta beslut om vad som ska produceras och hur mycket. 2. Leax Ett tillverkningsavsnitt som är fördelat på två separata men likadana flöden. För oss är avsnittet ovanligt då det dels producerar enbart en artikel men även för att de är starkt ihopbyggda flöden med robotar och banor. Dessutom finns duplicerad kapacitet på vissa maskiner i flödet men inte alla. Det är vårt avsnitt för tillverkning av Volvos synkroniseringsringar. Anledningen till att vi väljer synkringarna är att de är starkt i fokus för optimering samt som jag bedömer det bra avgränsat för som studieobjekt. Om det skulle vara så att tanken var flöden med fler artiklar för att simulera ställ och partistorlek så har vi sådana flöden också men då får vi diskutera fram vad som passar då komplexiteten ökar rejält. Målet skulle kunna vara att simulera fram eventuella systemfel dvs de förluster som kommer av hur vi har byggt flödena för att dels se vad vi egentligen kan förvänta oss rent teoretiskt i utfall, men även ge underlag för förbättringar. 3. Build upon previous studies in KPP206 Will be further presented and decided in the lecture 2012-09-25.
Grades Marks are set based on results from both the project work and the individual literature study Grading of individual study based on the extent and quality of the individual reflection, language and writing in PM. Grading of project the validity and relevance of the modeling and simulation of logic as well as visualisation, finally the language and writing of the report.
Plan Lectures Litterature study Seminar Project Presentation
Course web site http://zoomin.idt.mdh.se/course/kpp319/index.asp Visual Components / 3D Create information: http://www.visualcomponents.com/products/3dcreate Extendsim information: http://www.extendsim.com/prods_overview.html 13
W Date Time Lecturer Room Moment Curriculum 36 2012-09-04 13:15-16:00 Mats L249 Course intro 37 2012-09-11 13:15-16:00 Magnus L249 Lecture, Production system design 38 2012-09-18 13:15-16:00 Magnus L249 Guest lecture 39 2012-09-25 13:15-16:00 Magnus L249 Lecture, simulation and modeling of a production system 40 2012-10-02 13:15-16:00 Mats L3115 Lecture, discrete event simulation 41 2012-10-09 9-12 + 13-16 Johan Ernlund Simulation lab Visual Components 41 2012-10-12 9-12 + 13-16 Johan Ernlund Simulation lab Visual Components 42 2012-10-16 13:15-16:00 Mats/ Magnus L3115 Presentation of litterature study 43 2012-10-23 13:15-16:00 Mats /Magnus L3115 Project review 1 objective and plan 44 2012-10-30 13:15-16:00 L3115 Guest 46 2012-11-13 13:15-16:00 Mats /Magnus L3115 Project review 2 - draft model and indata 47 2012-11-20 13:15-16:00 Mats /Magnus L3115 Project review 3 - validation of model 48 2012-11-27 13:15-16:00 Mats /Magnus L3115 Project support 49 2012-12-04 13:15-16:00 Mats /Magnus L3115 Project review 4 results and conclusions from simulation study 50 2012-12-11 13:15-16:00 Mats /Magnus L3115 Final presentation of project 51 2012-12-18 13:15-16:00 Mats /Magnus L249 Final presentation of project
Visualisation lab Oct 9, 9.15 16.00 Name 15
Visualisation lab Oct 12, 9.15 16.00 Name 16
Lecture 1-2012-09-04 Course plan The course curriculum Schedules and lectures Projects assignment and groups Introduction to the subject What is industrial excellence?
Lecture 2 2012-09-11 Production system design Production system definition. Value chain models. Terminology. Abstraction levels. Design process. Phases. Steps. Product vs production design. Stake holders. Intro to Req spec s Intro to Modelling methods. Intro to Evaluation/Assessment methods Magnus Wiktorsson
Lecture 3 2012-09-18 Guest lecturer Farhad Nouruzi simulation study at Volvo CE
Lecture 4 2012-09-25 Simulation and modeling of a production system Intro to Req spec s Intro to Modelling methods. Intro to Evaluation/Assessment methods Magnus Wiktorsson
Lecture 5 2012-10-02 Discrete event simulation Simulation projects methodology Examples of simulation projects Case description - examples Mats Jackson
2012-10-09 or 2012-10-12 simulation lab An introduction to the software Visual Components The objective is to give an overview of the software and a help to start the projects Johan Ernlund
Lecture 6 2012-10-16 Presentation of the individual PM An individual reflection on future development regarding simulation as a tool within production and logistics management.
Lecture 7 2012-10-23 Project review 1 - objective, specification and plan Each team presents: the project objective and system specification project plan Each team gets: Comments, improvements, suggestions
Lecture 8 2012-10-30 Guest lecturer (to be confirmed) Alternatives Production system consultant Manufacturing simulation provider Researchers on production system design and performance Industrial researchers
Lecture 9 2011-11-13 Project review 2 - draft model and indata Each team presents: a draft model and required data to fulfill the project objective and system specification Data sources Updated project plan Each team gets: Comments, improvements, suggestions
Lecture 10 2012-11-20 Project review 3 - validation of model Each team presents: a presentation of the validation of the model input data for validation Updated project plan Each team gets: Comments, improvements, suggestions
Lecture 11 2012-11-27 Project support Mats Jackson, Magnus Wiktorsson Fady Ibrahim, Erik Hellström
Lecture 12 2012-12-04 Project review 4 results and conclusions from simulation study Each team presents: a presentation of simulations done The analysis from the simulation runs Results and conclusions Each team gets: Comments, improvements, suggestions
Lecture 13 2012-12-11 Final presentation of projects. Part 1. Teams presents: Project objective System specification Data sources Validation of the model Experiments Results and Conclusions
Lecture 14 2012-12-18 Final presentation of projects. Part 2 Teams presents: Project objective System specification Data sources Validation of the model Experiments Results and Conclusions
Comments on the course plan The course presupposes continuous participation, the students own studies and initiative and that all parts of the course are fulfilled within the time schedule of the course. Individual initiative is important Self studies Project supervision if needed ask for help
To-Dos Enroll to a date for Simulation lab: Start working on your individual PM. Start form Project groups (not urgent)
Industrial Excellence?
Industrial excellence Decisions, plans, guidelines Competences, Tools Methods Processes Production system design and development Production system operations Competences, Tools Methods Processes Experience, knowledge, data
What is a production system?
What is a production system? By Edward Burtynsky. DedaChicken Processing Plant, DehuiCity, Jilin Province, 2005.
The production system Transformation of input to products, from supplier to customer PRODUCTION SYSTEM Manufacturing Input Suppliers Parts Manufacturing Assembly Product System supplier
The Production System Hubka& Eder, 1996 Porter, 1985
Arsenaledi Venezia
Henry Ford
Model T The Model T was a great commercial success, and by the time Henry made his 10 millionth car, 9 out of 10 of all cars in the entire world were Fords. In fact, it was so successful that Ford did not purchase any advertising between 1917 and 1923. In total, more than 15 million Model Ts were manufactured, more than any other model of automobile for almost a century. 42
Toyota Production System
What is a competitive production system?
Globally increasing manufacturing activity Economic activity within Manufacturing 1998 2008, at constant 1990 prices in US dollars. Source: UN Stats A world wide 42% increase in manufacturing activity (at constant prices) 1998-2008. 36% increase in GDP world wide 1998-2008
The challenge of competing with production Demand of consumers are changing more rapidly than ever before Uncertainty of what products and what volumes to produce are larger than before Product life cycles are getting shorter Quick change-over in production between different products Quick phase in of new products Handeling changes and development
Production system changes
Production system changes Production system change Kaizen- Kaikaku - Kaizen Innovative and radical production system changes Time
What is production system development? Layout ofa new system An investment project Netz and Wiktorsson, 2009 A part in product development Development of production principles Muther, 1974 Ohno, 1988
Systems Engineering Fundamentals. 2001
Next Lecture Production system design Production system definition. Value chain models. Terminology. Abstraction levels. Design process. Phases. Steps. Product vs production design. Stake holders. Intro to Req spec s Intro to Modelling methods. Intro to Evaluation/Assessment methods Magnus Wiktorsson