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Production System DevelopmentJessica Bruch
● We needed to switch the date for the lectures from September 22 and October 2: September 22 13.15-15.00: Production
system start-up and production system performanceOctober 2 9.15-12.00: Sustainable
Production within ABB
OBS! Changes in the schedule:
● Terminology● Production system development as a means to
industrial excellence● Case work
Agenda
• A production system comprises all activities and resources needed in order to transform raw material into products.
Terminology
Olhager (2000)
Transformation
INPUTLabourCapitalNatural resourcesFacilityMachinery/ EquipmentMaterial Energy
OUTPUTProductsServices
INFORMATION
Customer contribution
● Trend: Productivity + Flexibility
Product - process matrix
Process
Product One of a kind, no
standardisation
Individual products
Low volume, multiple products
High volume, high
standardisation,commodity products
High volume, few
major products
Fixed position/ project
Functional layout
Line Flow/ Batch
Production line
Continous processing
Process
Hayes and Wheelwright, 2000, Hill, 2000
Flexibility
Productivity
Ship yardHeavy
equipmentFork lift trucks
Micro-waveoven
Oilrefinery
• Production development – design, impelementationand operation of production systems
• Design of production systems involves problem definition, identification of the goals, and to put forward different alternative solutions (problem solving). The result is a description of the production system to be (system solution).
• Development of production system includes besides the design of the system solution also the next stage, to implement the solution, which involves building and industrialisation of the production system. (Title of the course)
• Process development versus production system development
Terminology
More terminology
* Minor modification of the existing production system
PRODUCTION DEVELOPMENT
Production system development
Operation*
Production system design
Build the production
system
Production system start up
More terminology
PRODUCTION DEVELOPMENT
Production system development
Operation*
Production system design
Build the production
system
Production system start up
PRODUCT DEVELOPMENT
PRODUCT REALISATION PROCESS
* Minor modification of the existing production system
More terminology
PRODUCTION DEVELOPMENT
Production system development
Operation*
Production system design
Build the production
system
Production system start up
PRODUCT DEVELOPMENT
PRODUCT REALISATION PROCESS
INDUSTRIALISATION
Industrialisation: Those activities required to make the product manufacturable and to prepare production
Integrated production and product development
Andreasen and Hein, 1987
Products Products Production Production
Combining perspective
and and
• Developing a production system along with the product
• Cross-functional involvement in the development project
• Front-loaded project budget
• Strategic suppliers involved
Product design
Product design
Production Systemdesign
Production Systemdesign
Industrialization means combining perspectives
With the product EYE on…
• Reduce product complexity• Manufacturability (DFMA)• Configuration: modularity etc• Reduce number of variants• Tolerance setting• PPAP, PFMEA• Build prototypes• Prepare for pre-series
Product design
Product design Production
Systemdesign
Production Systemdesign
Industrialization means product and production system development in focus
With the production system EYE on…
• Design of a new production system, or change of existing one
• Holistic view: consider material, logistics, people, organization, technical system
• Buy or build equipment and machines
• Choose automation degree• Make/buy: sourcing• Footprint decision• Development of new
production technology
● Terminology● Production system development as a means to
industrial excellence● Case work
Agenda
Illustration: Mario Celegin
Why is it important to focus on production system development
Background
Time
Ability to frequently introduce new products
Model AModel B
Beforebased on Harlin, 2008
Few changes, few variantslong product life cycles
Model CModel C2
Model C3
Model FModel F2
Model F3
Model Z
Model ZxModel Zy
Frequent changes, several variants, short product life cycles
Today
Goal: to reduce time for running in and To reduce running-in problems
Time
Start of production
Pre-production Ramp-up Production
Production goal
Running-in of productionRate
Product - and Production problem
Time
Start of production
Pre-production Ramp-up Production
Production goal
Running-in of productionRate
Product - and Production problem
Ref. Bellgran and Säfsten (2010) modified from Johansson and Karlsson, 1998
Efficient industrialization –money to make and capability to do it
TTT TTM TTCTTV TTT = Time To Technology(time for conceptualdevelopment)
TTM = Time To Market (timefor introducing new product generations or variants)
TTV = Time To Volume (timefor ramp-up to full volume)
TTC= Time to Customer(order processingtime)…Time to Cash
Competing on time to volume
Focus on early phases
Start-up Targets
Time
Num
ber
of p
robl
ems
Prod
ucti
on ta
rget
s
ConceptDesign
TestInstallation
Lostproduction
Start-up
Targets
Time
Num
ber
of p
robl
ems
Prod
ucti
on ta
rget
sConceptDesign
TestInstallation
Lostproduction
Johansson och Nord, 1999
Aspects affecting development of production systems
The production system
The missing link
Production systemdesign and industrialization
Advantages of an effective production system development● Fast production ramp-up, i.e. ”time to cash”● Robust production systems● Increased market shares● Higher customer acceptance● Improved performance level related to productivity,
quality, and cost● Inward technology transfer● Difficult to compete and imitate by practitioners● ….
Competitive advantages
● Focus in on measuring and control of existing systems● Development of production systems is carried out ad-
hoc and without a long-term perspective● Much attention is devoted towards developing new
products● There are many different definitions and
interpretations of the process and work activities involved
● Focus is on the technical subsystem● Production systems are often developed according
to today’s products and strongly influenced by existing production systems
● ….
But in practice
Large unutilised potential
Identified difficulties
● Low priority● High complexity● No standardisation of what is development of
production systems● Includes a lot of no-engineering areas● Difficult to consider all aspects● Not only includes the technical system but also
humans that need to be integrated● ….
● Terminology● Production system development as a means to
industrial excellence● Case work
Agenda
Production system design situations
Product
new
modified
existing
newexistingmodified
Production system
mostcomplexsituation
Case A
Almgren, 1999
● Asier● Shilpa● Isabella● Avin
34
Project Group Volvo Cars
● Fredrik● Dennis● Kristina● Diana
35
Project Group AstraZeneca
● Pia● Martin● Camilla● Bent
36
Project Group ABB
● Julia● Alice● Sahel
37
Project Group Sense Air
● Critical definitions● Focus on the production system development process
is necessary for achieving industrial excellence● The development of production systems is complex
and challenging
38
Summary
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