Production System DevelopmentJessica Bruch

● We needed to switch the date for the lectures from September 22 and October 2: September 22 13.15-15.00: Production

system start-up and production system performanceOctober 2 9.15-12.00: Sustainable

Production within ABB

OBS! Changes in the schedule:

● Terminology● Production system development as a means to

industrial excellence● Case work

Agenda

• A production system comprises all activities and resources needed in order to transform raw material into products.

Terminology

Olhager (2000)

Transformation

INPUTLabourCapitalNatural resourcesFacilityMachinery/ EquipmentMaterial Energy

OUTPUTProductsServices

INFORMATION

Customer contribution

● Trend: Productivity + Flexibility

Product - process matrix

Process

Product One of a kind, no

standardisation

Individual products

Low volume, multiple products

High volume, high

standardisation,commodity products

High volume, few

major products

Fixed position/ project

Functional layout

Line Flow/ Batch

Production line

Continous processing

Process

Hayes and Wheelwright, 2000, Hill, 2000

Flexibility

Productivity

Ship yardHeavy

equipmentFork lift trucks

Micro-waveoven

Oilrefinery

• Production development – design, impelementationand operation of production systems

• Design of production systems involves problem definition, identification of the goals, and to put forward different alternative solutions (problem solving). The result is a description of the production system to be (system solution).

• Development of production system includes besides the design of the system solution also the next stage, to implement the solution, which involves building and industrialisation of the production system. (Title of the course)

• Process development versus production system development

Terminology

More terminology

* Minor modification of the existing production system

PRODUCTION DEVELOPMENT

Production system development

Operation*

Production system design

Build the production

system

Production system start up

More terminology

PRODUCTION DEVELOPMENT

Production system development

Operation*

Production system design

Build the production

system

Production system start up

PRODUCT DEVELOPMENT

PRODUCT REALISATION PROCESS

* Minor modification of the existing production system

More terminology

PRODUCTION DEVELOPMENT

Production system development

Operation*

Production system design

Build the production

system

Production system start up

PRODUCT DEVELOPMENT

PRODUCT REALISATION PROCESS

INDUSTRIALISATION

Industrialisation: Those activities required to make the product manufacturable and to prepare production

Integrated production and product development

Andreasen and Hein, 1987

Products Products Production Production

Combining perspective

and and

• Developing a production system along with the product

• Cross-functional involvement in the development project

• Front-loaded project budget

• Strategic suppliers involved

Product design

Product design

Production Systemdesign

Production Systemdesign

Industrialization means combining perspectives

With the product EYE on…

• Reduce product complexity• Manufacturability (DFMA)• Configuration: modularity etc• Reduce number of variants• Tolerance setting• PPAP, PFMEA• Build prototypes• Prepare for pre-series

Product design

Product design Production

Systemdesign

Production Systemdesign

Industrialization means product and production system development in focus

With the production system EYE on…

• Design of a new production system, or change of existing one

• Holistic view: consider material, logistics, people, organization, technical system

• Buy or build equipment and machines

• Choose automation degree• Make/buy: sourcing• Footprint decision• Development of new

production technology

● Terminology● Production system development as a means to

industrial excellence● Case work

Agenda

Illustration: Mario Celegin

Why is it important to focus on production system development

Background

Time

Ability to frequently introduce new products

Model AModel B

Beforebased on Harlin, 2008

Few changes, few variantslong product life cycles

Model CModel C2

Model C3

Model FModel F2

Model F3

Model Z

Model ZxModel Zy

Frequent changes, several variants, short product life cycles

Today

Goal: to reduce time for running in and To reduce running-in problems

Time

Start of production

Pre-production Ramp-up Production

Production goal

Running-in of productionRate

Product - and Production problem

Time

Start of production

Pre-production Ramp-up Production

Production goal

Running-in of productionRate

Product - and Production problem

Ref. Bellgran and Säfsten (2010) modified from Johansson and Karlsson, 1998

Efficient industrialization –money to make and capability to do it

TTT TTM TTCTTV TTT = Time To Technology(time for conceptualdevelopment)

TTM = Time To Market (timefor introducing new product generations or variants)

TTV = Time To Volume (timefor ramp-up to full volume)

TTC= Time to Customer(order processingtime)…Time to Cash

Competing on time to volume

Focus on early phases

Start-up Targets

Time

Num

ber

of p

robl

ems

Prod

ucti

on ta

rget

s

ConceptDesign

TestInstallation

Lostproduction

Start-up

Targets

Time

Num

ber

of p

robl

ems

Prod

ucti

on ta

rget

sConceptDesign

TestInstallation

Lostproduction

Johansson och Nord, 1999

Aspects affecting development of production systems

The production system

The missing link

Production systemdesign and industrialization

Advantages of an effective production system development● Fast production ramp-up, i.e. ”time to cash”● Robust production systems● Increased market shares● Higher customer acceptance● Improved performance level related to productivity,

quality, and cost● Inward technology transfer● Difficult to compete and imitate by practitioners● ….

Competitive advantages

● Focus in on measuring and control of existing systems● Development of production systems is carried out ad-

hoc and without a long-term perspective● Much attention is devoted towards developing new

products● There are many different definitions and

interpretations of the process and work activities involved

● Focus is on the technical subsystem● Production systems are often developed according

to today’s products and strongly influenced by existing production systems

● ….

But in practice

Large unutilised potential

Identified difficulties

● Low priority● High complexity● No standardisation of what is development of

production systems● Includes a lot of no-engineering areas● Difficult to consider all aspects● Not only includes the technical system but also

humans that need to be integrated● ….

● Terminology● Production system development as a means to

industrial excellence● Case work

Agenda

Production system design situations

Product

new

modified

existing

newexistingmodified

Production system

mostcomplexsituation

Case A

Almgren, 1999

● Asier● Shilpa● Isabella● Avin

34

Project Group Volvo Cars

● Fredrik● Dennis● Kristina● Diana

35

Project Group AstraZeneca

● Pia● Martin● Camilla● Bent

36

Project Group ABB

● Julia● Alice● Sahel

37

Project Group Sense Air

● Critical definitions● Focus on the production system development process

is necessary for achieving industrial excellence● The development of production systems is complex

and challenging

38

Summary