Causal and temporal relationships within the combination of Lean Production Systems and Industry 4.0

Pascal Langlotz, Jan C. Aurich
2021 Procedia CIRP  
In today's business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to analyze a product or one product family on the physical level. Different product
more » ... ies, however, may differ largely in terms of the number and nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the similarity between product families by providing design support to both, production system planners and product designers. An illustrative example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach. Abstract The concept of Lean Production System is applied in manufacturing systems around the globe. With the help of avoidance of waste on the shop floor and a holistic view of the manufacturing system, efficient processes are created. The concept of a Lean Production System with its principles and tools is influenced by a newer concept that is increasingly introduced in manufacturing systems as well, named Industry 4.0. Here, the connection of every resource, object, and human in real-time is aspired to handle future production problems. Such problems are, for example, the high demand for customized products that require a high degree of flexibility. Numerous researches address the combination of both concepts to create an efficient and also a flexible manufacturing system. However, an investigation of the relationships of these combinations is still missing. In this paper, the relationships of a method library, which links the concept of Lean Production System and Industry 4.0, are analyzed. Especially the causal and temporal relationships are examined. These relationships establish the interdependencies between the methods of Lean Production Systems and the technologies of Industry 4.0 and their implementation order. Abstract The concept of Lean Production System is applied in manufacturing systems around the globe. With the help of avoidance of waste on the shop floor and a holistic view of the manufacturing system, efficient processes are created. The concept of a Lean Production System with its principles and tools is influenced by a newer concept that is increasingly introduced in manufacturing systems as well, named Industry 4.0. Here, the connection of every resource, object, and human in real-time is aspired to handle future production problems. Such problems are, for example, the high demand for customized products that require a high degree of flexibility. Numerous researches address the combination of both concepts to create an efficient and also a flexible manufacturing system. However, an investigation of the relationships of these combinations is still missing. In this paper, the relationships of a method library, which links the concept of Lean Production System and Industry 4.0, are analyzed. Especially the causal and temporal relationships are examined. These relationships establish the interdependencies between the methods of Lean Production Systems and the technologies of Industry 4.0 and their implementation order.
doi:10.1016/j.procir.2021.01.080 fatcat:hgu5er2rfvdqhpbnzxd4257hwm