Krzysztof Żywicki

Influence of Selected Methods of Production flow Control on Environment

The chapter presents issue of influence of everyday activity of manufacturing enterprises on the environment. Authors draw attention to how great impact on the state of the environment have decision taken by production managers. Special attention is drawn to, inter alia, redundant transport during production processes and also generation of waste during production. In the chapter methods of production flow control are presented and compared them in terms of impact of the result of using it on the environment. In group of methods which are discussed are methods of family MRP - material requirements planning (MRP I), manufacturing resource planning (MRP II) and enterprise resource planning (MRP III / ERP). It is also analyzed optimized production timetable (OPT) and the Japanese methods of production flow control (JIT, KANBAN). At the end of article indicate of those methods of production flow control which are least harmful to the environment.

Preparation and Production Control in Smart Factory Model

Implementing the smart factory concept places demands not only for enterprises but also for scientific units. In order to be able to effectively develop solutions in compliance with the Industry 4.0 concept, it is necessary to improve qualifications of scientific personnel and students who are supposed to implement those assumptions in practice. The paper describes the structure of smart factory model, developed at Poznan University of Technology, which enables both learning about such solutions and doing research work in that scope. The model includes issues connected with the field of production management – starting from interpretation of client requirements, to automation of product design development, to preparing and controlling the production process.

Data Analysis in Production Levelling Methodology

The article describes an original computer program developed by the authors to aid data analysis for the purposes of production levelling methodology. Individual stages of the methodology are connected with analysis of multiple types of data. The program AnaPro enables analysis of manufacturing process data to separate product families, specify the demand for products and implement production. Functions of the program are described along with examples of data analysis.

Soft Modelling-Based Methodology of Raw Material Waste Estimation

The paper looks at soft modelling-based estimation of raw material waste for various variants of a technological process under development. A methodology of assessment of new technology variants, in terms of minimization of the input material waste, is presented. Results of an analysis of variants of a new technology of manufacturing of the middle layer of a flooring board, carried out according to the developed methodology, are shown. The assessment is performed in an original software tool for waste simulation. It is shown that the developed methodology supports the estimation of material waste and assists in the selection of the optimal variant of the process, taking into consideration the constraints of the organization.

Virtual Reality Production Training System in the Scope of Intelligent Factory

The paper presents a prototype Virtual Reality system for learning of operation in an intelligent factory, working according to the concept of Industry 4.0. The SmartFactory laboratory—example of part of intelligent factory—is described. The VR prototype system and process of its building is also presented, starting from digitalization of the real smart factory, through logic programming and connection of peripheral VR devices. Functions of the training system are presented, along with directions of future studies and development.

Improving Production Flexibility in an Industrial Company by Shortening Changeover Time: A Triple Helix Collaborative Project

This chapter presents a triple helix collaborative project carried out through the collaboration of members of three Universities in order to analyze the impact of shortening changeover time on production flexibility in an Industrial Company. The project has been developed for a production company, whose products are fibreboard, hardboard, and soft board products manufactured by a highly specialized Industry using only pure wood fibres. The main reason why it was decided to complete the project was the existence of too long lead times, which meant that many orders were delayed. The main objectives of the project were to reduce changeover times and to increase production flexibility. Therefore, changeover time was analyzed to understand if some activities could be eliminated, moved or simplified. The implemented solution has resulted in shortened lead time, improved workflow, reduced costs of line putting in readiness, standardized changeovers, and has significantly contributed to improving the competitiveness of the Company on the market.

Methodology Supporting the Planning of Machining Allowances in the Wood Industry

The paper presents a methodology of determination of technological allowances in the manufacturing process of semi-products of deciduous timber (oak). Soft modelling has been proposed for the determination of allowances for the variability of consecutive technological processes caused by the material, machine, operator, measurement system and random factors. The proposed methodology has been applied in the technological process of manufacturing the surface layer of a floor board (lamella). The method of identification of a soft model for the process of cutting timber into lamellas has been presented. Twenty soft models have been identified and recommendations have been made, based on experiments, for reducing the variability and centering the process. The proposed process modelling method facilitates economic estimation of allowances, controlling the manufacturing process and forecasting its future condition. As a result of the research, the manufacturing capacity of lamellas of acceptable quality has been increased by ca. 30%.

Computer Aided Data Acquisition and Analysis for Value Stream Mapping

The article presents original computer software designed to assist in data acquisition and analysis for the purpose of value stream mapping for one of tools of lean manufacturing concept. The AnaPro program uses the collected data about manufacturing processes to analyse product demand, material supplies or manufacturing processes, which is then used as a basis for creating current state maps. Furthermore, the program allows for preparing variants of future state maps through an analysis of turnover classification, product demand and methods of production flow control. The article describes functions of AnaPro with regard to value stream mapping and a practical example of the software application is provided.

Efficiency of Automatic Design in the Production Preparation Process for an Intelligent Factory

This article presents the research on the efficiency of performance of automatic design of variant products system, including the process of product variant configuration, preparation of the 3D model in CAD system and the preparation of the assembly instructions for the manufacturing positions. The variants of the described product take the form of various combinations of individual assembly parts combined together and constitute an example of customized products, and the process of their manufacture (assembly) is the subject of the research carried out in the SmartFactory Laboratory at the Poznan University of Technology.

Methodology of Estimating Manufacturing Task Completion Time for Make-to-Order Production

Timely delivery of products designed to individual requirements of customers is increasingly difficult for manufacturers. It results from difficulties in effective development of production schedules and material flow control. The reason is, among other things, the lack of real data on standard times required to complete individual manufacturing processes. This article presents the assumptions on the method of estimating standard times for highly individualized products. The proposed method has been incorporated into computer software that was verified at an actual production company that manufactures electric heating elements.