Sebastian Weckenborg

Method-Supported Product Development for Post-series Supply

The increased use of innovative components like electronics is a present trend in several branches of industry. These components are characterized by short innovation cycles, but are often assembled in primary products, which have a comparatively long life span. The post-series supply is therefore a relevant problem. Today the focus of product development lies on small expenses in the serial production, a consideration of life cycle costs with regard to the post-series supply does not take place. This behavior often results in high financial burden. Before this background the product development with consideration of the requirements of the post-series-supply offers high potentials. To reduce the complexity of this problem a methodical approach is needed.

Determination of the Spare Parts Demand for Maintenance, Repair and Overhaul Service Providers

Service providers for maintenance, repair and overhaul (MRO) of aircrafts and components face major challenges. The calculation of an optimal stock level for components is one of these. The optimal stock level is highly influenced by the customers demand. Furthermore the stock level influences the profitability of the processes. The challenge for MRO service provider is to respond to the changing customer base and to adapt the stock level for components dynamically. For this purpose, an approach for the determination of the spare parts demand is described in this paper. The approach consists of a hierarchical derivation of reliability parameters in the first step and finally an assessment of the derived reliability parameters. By this assessment the relevance of different impact factors can be determined. The determination of the spare parts demand and the optimal stock level can thereby be determined much more accurately.

Demand Control Loops for a Global Spare Parts Management

Timely, reliable supply of customers with spare parts is a key factor for business success in many branches. In the field of aviation the competition and cost pressures in the MRO sector (Maintenance, Repair and Overhaul) increased strongly in recent decades. Large maintenance organizations offer component pooling services for aircraft operators. A main challenge in the processes of MRO service providers is the calculation of the optimal stock level for pool components. The basis of an optimal inventory planning for the supply of spare parts is the quality of the demand input parameters used for the calculation. This paper describes the processes and the challenges of the MRO spare parts management as well as the approaches of a research project to face these challenges.

Consideration of Changing Impact Factors for Optimization of Post-series Supply

The increased use of electric and electronic components is a trend in several branches of industry. The short life cycles of these innovative components compared with the life cycles of the primary products lead to challenges regarding an effective spare parts management. To guarantee an availability of spare parts during the whole period of the post-series supply, a period of up to 15 years in the automobile industry, a structured planning process is needed. The current approaches for the planning of the post-series supply concentrate on static impact factors to evaluate a supply scenario for the post-series supply, but for a detailed assessment of possible supply strategies changing impact factors have to be considered. A methodical approach for this will be described in this paper.

Evaluation of Post-series Supply Strategies in Regard of Sustainability

The use of electronic components is rising in industries like the automobile industry since several decades. The characteristics of these parts are different to these of mechanical components, especially with regard to the spare parts management. Today economical aspects and technological restrictions are in the main focus of the planning process for the post-series supply. However the ecological impact of the post-series supply is not considered in this process. Often the economic and the ecologic preferable strategy are conflictive. The consideration of these two aspects with regard to the technological feasibility is a complex problem. One possible solution to consider these aspects simultaneously and to increase the sustainability of the products and processes is the design of electronic components according to the requirements of post-series supply.

A Multi-Touch Planning Table to Support Participatory Factory Planning

The factory as a place of value-adding activities is forced to adapt continuously to turbulent conditions. New requirements regarding flexibility, speed, mobility and cost efficiency are some of factory planning. Hence the role of factory planning has developed from a one-time activity to a continuous management task. To achieve optimal results with regard to the new requirements it is necessary to analyze the existing processes and the functionality of the technical equipment at the workplace in detail. Therefore the existing methods of factory planning have to be improved. This paper focuses on the improvement of factory layout planning methods. One of the main areas of research of the Institute for Production Management and Enterprise Research (IFU) is the participatory layout planning. The goal of the research activities is to develop a method to integrate the employees from the shop-floor level into the planning process since they have special knowledge of the processes and technical equipment, which is necessary to achieve optimized planning results. To support the implementation of the participatory factory planning the IFU — in co-operation with the foresee GmbH — started the development of a participatory planning table called T3Pad (Tangible table top to enhance participation and development). The T3Pad is a conventional conference table with an integrated multi-touch display. The use of a gesture based software for layout planning offers the factory planning team the opportunity to design a layout by using the existing knowledge of the “classic” planning departments as well as the special manufacturing experience of the shop-floor employees. In order to realize the participation of the whole planning team the software has to comply with two major requirements: on the one hand the requirement in terms of the database and rules of factory planning; on the other hand the requirement of the usability of the software interfaces. Until now the users of factory planning methods have to adapt themselves to the function mode of computers instead of interacting and communicating in an intuitive way. This leads to limited interaction between user and hardware. The main goal of the T3Pad is an optimal support of the user by the software interface. To reach this goal the IFU started a field study to analyze the adoption of gesture based software interaction.Copyright

Outsourcing von Elektronikkomponenten in der Nachserienversorgung

Kurzfassung Eine durchgehende Ersatzteilversorgung von Elektronikkomponenten ist für die langfristige Nutzung der Primärprodukte, in denen sie verbaut sind, erforderlich und daher auch ein wesentliches Kriterium für eine nachhaltige Kundenzufriedenheit. Nach dem Ende der Serienproduktion ergeben sich jedoch veränderte Rahmenbedingungen. Die Hersteller sind auf die volumenstarke Serienproduktion spezialisiert und haben erhebliche Probleme, die geringen Losgrößen in der Nachserie zu wirtschaftlichen Konditionen zu fertigen. Durch den verstärkten Einsatz von elektrischen, elektronischen und mechatronischen Bauteilen, beispielsweise in der Automobil- oder Luftfahrtindustrie, ergeben sich zusätzliche Anforderungen für die Nachserienversorgung, die mit den klassischen Methoden des Ersatzteilmanagements nicht bewältigt werden können. Die Fremdvergabe der Fertigung an spezialisierte Elektronikfertiger ist eine Möglichkeit zur Fokussierung auf die Kernkompetenzen. Im vorliegenden Artikel sollen der Prozess des Outsourcings von Elektronikkomponenten in der Nachserienfertigung, die Besonderheiten und Probleme beschrieben werden.

Integration von Kunden in bestehende Instandhaltungssysteme: Ersatzteilmanagement in der Luftfahrtindustrie

Kurzfassung Der starke Wettbewerb in der Luftfahrtindustrie zeigt sich ebenfalls im Bereich der Instandhaltung und dem Ersatzteilmanagement von Komponenten. Um die wirtschaftliche Versorgung mit Komponenten sicherzustellen, werden diese Tätigkeiten vielfach an Instandhaltungsdienstleister vergeben. Instandhaltungsdienstleister müssen hierbei zum Teil erhebliche Herausforderungen bewältigen, die sich bei der Integration neuer Kunden bzw. neuer Kundenerzeugnisse bemerkbar machen.

Ersatzteilmanagement in der Luftfahrtindustrie

Kurzfassung Die wirtschaftliche Versorgung von Flugzeugen mit Komponenten stellt eine wesentliche Herausforderung für Instandhaltungsdienstleister in der Luftfahrtindustrie dar. Zur exakten Bedarfsermittlung werden unterschiedliche Einflussfaktoren berücksichtigt, wobei der Nutzungsintensität einer Komponente eine große Bedeutung zukommt. Die Nutzungsintensität weist in der Luftfahrtindustrie jedoch unterschiedliche Dimensionen auf. In diesem Artikel wird ein Ansatz beschrieben, der es ermöglicht, die unterschiedlichen Dimensionen der Nutzungsintensität zu gewichten und damit die Qualität der Bedarfsermittlung zu steigern.

Fabrikplanung für die Nachserienversorgung

Kurzfassung Der steigende Anteil von Elektronikkomponenten in langlebigen Primärprodukten stellt neue Herausforderungen an die Sicherstellung der Ersatzteilversorgung. Ein Grund hierfür sind die kurzen Bauteillebenszyklen im Bereich der Elektronik im Vergleich zu den langen Versorgungszeiträumen, die weit über das Ende der Serienproduktion hinaus reichen. Die Fertigung ist auf die volumenstarke Serienproduktion ausgelegt und eine wirtschaftliche Produktion in der Nachserie ist innerhalb bestehender Strukturen kaum möglich. Um den Rahmenbedingungen der Nachserie angemessen begegnen zu können, ist die Neugestaltung der Produktion oder die Verlagerung dieser in besondere Produktionsbereiche notwendig. Die Identifikation der Einflussfaktoren der Nachserienversorgung sowie die Berücksichtigung der daraus resultierenden Anforderungen stellt die Fabrikplanung vor neue Herausforderungen. In diesem Artikel werden wesentliche Einflussfaktoren auf die Fabrikplanung zur Sicherstellung der Nachserienversorgung von Elektronikkomponenten beschrieben.