Jochen Deuse

Gestaltung von Produktionssystemen im Kontext von Industrie 4.0

Die Erfahrungen aus der Vergangenheit zeigen deutlich, dass weder ausgepragte technik- noch humanzentrierte Gestaltungsparadigmen zu einer nachhaltigen und deutlichen Verbesserung der Wettbewerbsfahigkeit beitragen, sondern u. U. sogar negative Auswirkungen haben konnen. Im Gegensatz dazu konnten mit organisationszentrierten Ansatzen zur Gestaltung von Produktionssystemen deutliche Fortschritte in der Verbesserung der Wettbewerbsfahigkeit erzielt werden. Die Hypothese lautet, dass der Erfolg der ausgerufenen vierten industriellen Revolution wesentlich davon abhangt, ob es gelingt diese nachhaltig in der Organisation zu verankern und zielgerichtet umzusetzen. Humane und technische Aspekte sind demzufolge an die Strukturen und Prozesse der Organisation anzupassen und auszurichten. Dabei besteht in einem zunehmend dynamischen und komplexen Wettbewerbsumfeld fur Unternehmen die Moglichkeit, die Arbeits- und Organisationsgestaltung in verschiedene Richtungen zu entwickeln. Im Rahmen eines organisationszentrierten Ansatzes ist im Sinne der soziotechnischen Arbeits- und Produktionssystemgestaltung die systemische Prozesssicht in den Vordergrund zu rucken. Konkret erfordert die Gestaltung von CPPS u. a. neue dezentrale Fuhrungs- und Steuerungsformen, neue kollaborative Formen der Arbeitsorganisation mit einem hohen Mas an selbstverantwortlicher Autonomie, einen verstarkten Aufbau entsprechender Systemkompetenz sowie damit einhergehend eine wachsende technische Unterstutzung auf Basis der Anpassung der Arbeit an den Menschen.

Multi-objective optimization of facility planning for energy intensive companies

Because of the energy shortage and energy price rise, energy efficiency becomes a worldwide hot spot problem. It is not only a problem about cost reduction, but also a great contribute to the environmental protection. However, the energy efficiency was always ignored in the past decades. In order to gain more benefit and become more competitive in the market, energy efficiency should be considered as an essential factor in early planning phase. To overcome these problems, a new approach, which introduces energy efficiency as a key criterion into the planning process, is presented in this article. An energy recovery network is built according to the analysis of process and product demands. Afterwards the energy loss of the whole system, transport performance and space demand are simultaneously taken into account with the purpose of finding good facility planning from both energy and economic aspects. Finally, a practical expanding case is used to validate the correctness and effectiveness of the proposed approach.

A Planning Approach for In-plant Milk Run Processes to Optimize Material Provision in Assembly Systems

In order to face current trends for manufacturing companies, production logistics and especially material provision is one of the key aspects for optimizing assembly systems. Automotive companies adapt their logistics processes to the needs of assembly resulting in new material supply concepts like in-plant milk runs. However, this concept is rarely implemented in other industries due to its complexity in planning and dimensioning in comparison with traditional conveying systems. Furthermore, in-plant milk runs are not thoroughly described and explained in logistics or lean production literature. This paper focuses on a new approach for planning and optimizing in-plant milk run processes to allow assembly and logistics planners faster reconfiguration of material provision systems.

Systematic improvement of value streams - fundamentals of value stream oriented process management

Improving processes is a daily base challenge for enterprises. In particular improvement attempts occur in various different levels of detail and are commonly not linked methodically. Process management systems in general are suitable approaches to manage process improvements. A systematic routine to improve processes and value stream mapping (VSM) are integrated into the organisational framework of process management in order to enable a methodically fostered improvement of value streams in different levels of detail. The outlined approach to systematise the application of VSM is the conjunction of volatile and short-cyclic improvements of a value stream and the determination of target-conditions in order to develop the value stream towards an ideal-state which is specified by productivity and quality criteria.

Application Protocols for Standardising of Processes and Data in Digital Manufacturing

To increase the efficiency of planning tasks the use of Digital Manufacturing (DM) software is state of the art for manufacturing companies in automotive and aerospace industries. Many of these companies deploy heterogeneous software environments often including many specialised but isolated IT-tools. In order to enable a continuous and reconfigurable planning workflow in DM the integration of planning tools and their data models will gain more and more importance. In this paper an approach for the integration of processes and data is introduced. Application-specific data models, so called Application Protocols, are used to standardise processes and data in DM and enable flexible software architecture. The methodology is validated by using the results in commercial software interfaces.

Morphology of time data management – systematic design of time data management processes as fundamental challenge in industrial engineering

During the last 10 to 15 years, a renaissance of industrial engineering can be observed in manufacturing industry, as well as in scientific research. As a consequence, time and motion studies (TMS) become more important again. During the downturn of methodical approaches in industrial engineering in the 1980s, TMS-related competencies were lost in industry. Many companies are still missing the know-how for establishing a proper time data management (TDM). This paper presents a morphology of time data management (MoTDM), which was developed in order to create a comprehensive view on the processes of TDM as well as to detect relevant areas of improvement. The MoTDM can be used to optimise TDM processes within a company and also acts as scientific fundament for research in the field of industrial engineering.

Knowledgebase für die kontinuierliche Innovationsarbeit im Technischen Kundendienst

Service-Mitarbeiter im Technischen Kundendienst sind die Wissenstrager von Dienstleistungsorganisationen und konnen wesentliche Treiber fur Innovationen sein. Dafur ist ihr Wissen nachhaltig zu erfassen und soweit moglich mit allen Service-Mitarbeitern zu teilen, damit diese die Dienstleistungsprozesse durch eine kontinuierliche Innovationsarbeit gemeinsam verbessern konnen. Dieses kann durch eine Standardisierung der Dienstleistungsprozesse erreicht werden. Dabei sind diese Standards nicht als Dogma, sondern vielmehr als verbindliche Handlungsanweisungen zu verstehen, die es permanent zu verbessern gilt. Der folgende Beitrag stellt den Bedarf und die Umsetzung des im ersten Band vorgestellten Konzeptes vor.

The Industrial Engineering Laboratory

This paper presents how Problem Based Learning is integrated in Industrial Engineering higher education provided by the Industrial Engineering Laboratory at TU Dortmund University in Germany. After pointing out the necessary asset of competences for Industrial Engineers as the intended learning outcome, Problem Based Learning is presented as one appropriate concept for competence development in higher education in engineering. The implementation of this explicit course design and its advantages is shown by explaining the specific course example “Workplace Design” in detail, which is carried out in a hands-on laboratory - the Industrial Engineering Laboratory.

Combining Planning and Simulation to Create Human Robot Cooperative Processes with Industrial Service Robots

The integration of lightweight robots and service robots into industrial work places forms the new area of industrial service robots characterized by the transformation of manual processes to human robot interactive processes. Still, it is highly difficult to decide which manual processes are qualified for automation or collaboration. Consequently, only few collaborative processes can be found in industry. The objective of the project MANUSERV is to support decisions towards this transfer by developing a tool that supports users to identify practical technical solutions. The tool is a combination of a planning system and a simulation system. The aim of the planning system is to select technically feasible solutions and generate task sequences that solve the problem. The simulation system verifies the proposed solution and evaluates it technically, economically, and ergonomically. Manufacturers of service robots can provide their service robot specifications to be included into the system selection process.

Challenges for Data Mining on Sensor Data of Interlinked Processes

In industries like steel production, interlinked production processes leave no time for assessing the physical quality of intermediate products. Failures during the process can lead to high internal costs when already defective products are passed through the entire value chain. However, process data like machine parameters and sensor data which are directly linked to quality can be recorded. Based on a rolling mill case study, the paper discusses how decentralized data mining and intelligent machine-to-machine communication could be used to predict the physical quality of intermediate products online and in real-time for detecting quality issues as early as possible. The recording of huge data masses and the distributed but sequential nature of the problem lead to challenging research questions for the next generation of