Sebastian Horbach

Production system planning in Competence-Cell-based Networks

Autonomous, elementary units of production, cooperating in temporary networks, are considered as a key organizational form of enterprises in the 21st century. A scientific approach is provided by networks based on customer-oriented, directly linked, smallest autonomous business units called Competence Cells. Models for Competence Cells and their networking were developed. For such networks also, an operationalized concept of organization is needed. With the ‘Holistic Integration Method’ (HIM), an organizational manual is provided. The general architecture of the Holistic Integration Method consists of the levels ‘Portal’, ‘Process Engine’ and ‘Methods and Tools’. The concept of Competence-Cell-based Networks leads to new requirements for the planning of production systems of such networks. Therefore, a framework called ‘PlaNet—Planning Concept for Networks’ has been developed. PlaNet, which is a component of HIM, provides the means that enable the Competence Cells to solve their planning problems. The framework includes methodical and default components for planning and designing logistics structures and production plants. The suitable basis for PlaNet has been found with the Systems Engineering Methodology (SE). Thus, the components of the methodical concept of PlaNet are derived from the components of SE. The Net Planning Assistant with its Production Database is a toolset which comprises software implementing the methods of PlaNet including tools for participative planning.

Approaches for planning and operation of adaptable factories

Adaptability is currently one of the most challenging research topics. The Department of Factory Planning and Factory Management of Chemnitz University of Technology developed the Experimental and Digital Factory in which building blocks for adaptable factory systems are integrated. Hence, a powerful model factory is available for research on adaptability. The focus among others is on the continuous interaction between factory planning and factory operation. This includes an extensive interchange and processing of information between the virtual and the real factory. The rapid implementation and verification of planning results in the real environment is enabled by holistic application and integration of different methods and tools of the Digital Factory. The paper explains a concept for adaptable factory systems and the interplay of planning and operation. The approaches are demonstrated on the use case of combined planning of layout and logistics with subsequent realisation.

Integrative planning and design of logistics structures and production plants in Competence-cell-based networks

The approach of Competence-cell-based networks presents a special challenge to the planning and design of logistics structures and production plants. On the one hand a highly flexible and fast planning and design is required. On the other hand this is contrasted by the need for simple, rational and user friendly planning and design. To fulfil these increased requirements the modular Planning Concept for Networks (PlaNet) was developed. With PlaNet a set of rules was created, which supports Competence Cells in an integrated solving of different problems. As a suitable basis for PlaNet, the Systems Engineering (SE) methodology was chosen. If the components of the SE are understood as basic structure, the components of PlaNet are derived from them. Important components are the procedure logic, planning cases, the holistic planning method, principles of planning, the Method of Integrated Process and System Structuring (IPSS), the method of component-based planning and the Net Planning Assistant (NPA).

Building Blocks in an Experimental and Digital Factory

Factory planning has to respond to demands for changeable and agile factory systems. The adaptability of the production system can be improved by using adaptable building blocks. Adaptable building blocks are implemented in an Experimental and Digital Factory (EDF). The paper presents the components of the EDF. First the products are introduced. Then the building blocks of the experimental and the digital parts are presented. Finally, the interweaving between the experimental and the digital part is explained. That means, the real production is mapped into the virtual world so that the configuration can be assessed with planning tools. The automatically controlled operation of the Experimental Factory will be discussed.

Agile Planning Processes

The paper explores the requirements and support systems for agile planning processes. It reviews therefore traditional planning processes and proposes a new model based on agile principles. The novel planning model is employed to frame a component-based planning approach and its application in a planning manual.

Implications of Interoperability for Factory Planning

Enterprises operate in an increasingly turbulent environment. In order to stay competitive, more and more complex decisions have to be taken. Production systems are not relatively closed systems any more, but often part of supply networks with a high number of resulting interfaces. Planning and operation of factories are tightened together. At the same time virtual reality, as the mean of modern factory planning, merges with the real world. The processes of planning and operation are supported by a variety of software tools. With reference to operation of enterprises a lot of effort is put in integrating the different tools, while there is a deficit concerning the integration of factory planning tools. Therefore, the paper will look at the current state of interoperability in factory planning. The requirements and use cases of data exchange between tools for factory planning as well as other enterprise software, are discussed. Thereby, challenges and opportunities resulting from better hardware performance, faster communication networks and a wide range of new types of devices are listed. The consequences of trends like cloud computing and big data are classified. Conclusions are derived for possible architectures of software systems. The role of the Digital Factory in the whole development is investigated.

Decentralised Decision Making in Non-Hierarchical Networks

Autonomous, elementary units of production, co-operating in temporary networks, are considered as the organisational form of enterprises in the 21st century. A scientific approach is provided by networks based on customeroriented, directly linked, smallest autonomous business units called Competence Cells. Simultaneously this concept points out perspectives for present-day small and medium-sized enterprises (SME) to face ever-changing economic conditions. One objective is to make SMEs fit for global supply chain integration as well as collaborative management of complex manufacturing and logistics tasks in several production networks at the same time. For a decentralised decision making based on the non-hierarchical business model special business logics, algorithms and methods for supply chain integration and management need to be provided and implemented in services and applications. A first core logic is focused on the matching of partners for composition and operation of temporary production networks. Contrary to existing web portals the basic idea is to make the linking interactive and more flexible by using of different description constructs regarding to satisfy the customer, but also network goals. A second core logic addresses the cascading selection of the partners for a customer order driven supply chain. Firstly the “nodes” (manufacturing, assembly, testing) have to be chosen, secondly the “relations” (logistics). A third core logic deals with these “relations”. The idea is to establish an automated determination of the logistic processes and candidates.

Collaborative Planning in Competence-Cell Based Networks

Autonomous, elementary units of production, co-operating in temporary networks, are considered as a key organisational form of enterprises in the 21st century. A scientific’ approach is provided by networks based on customer- oriented, directly linked, smallest autonomous business units called Competence Cells’. This approach leads to new requirements for the planning of production systems of such networks. To meet them a framework called ‘PlaNet - Planning Concept for Networks’ has been developed and is outlined. PlaNet provides the means for Competence Cells to solve their planning problems. The implementation of PlaNet is the Net Planning Assistant as a modular toolset.

Planning of Flow of Material and Energy for Photovoltaics Industry

Abstract Due to the continuously increasing need for renewable energy, the demand for photovoltaic components is significantly growing. Therefore, many highly productive factories for solar cells will be built in the coming years. The development of tools and methods for rapid planning of state of the art and highly automated production facilities for photovoltaic equipment is the objective of the Saxon PV Automation Cluster (S-PAC). So far the focus of factory planning was strongly on discrete part manufacturing while in contrast the production of solar panels involves a lot of chemical processes with different by-products, even though the final output is discrete parts. Hence, it is investigated how methods and tools of discrete manufacturing still can be applied to photovoltaic industry or where adaptations are necessary. From a methodical point of view the Flow System Theory, comprising material, energy, information, value and personnel flow, as well as Component-based Planning, considering planning process and object components, will be in the focus. While in the past the emphasis was on the optimisation of the material flow, the significance of the energy flow is increasing. The realisation of the information flow requires appropriate tool support. The base of the tool support is provided by the concept of the Net Planning Assistant with the Production Database as central storage component. The Production Data Model as foundation for the Production Database has to be adapted to the differing object domain. A reference database of typical objects of photovoltaic cell, wafer and module production is developed as a basis for datasets of particular projects. Models for visualisation and simulation of the photovoltaic objects are connected to the data model. Interfaces to the Manufacturing Execution System (MES) and the quality management system need to be defined.