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Sustainable Manufacturing and Factory Planning Introduction 03.04.2017 Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl © IWF TU Berlin Page 1 Content  Organizational Issues  Technology and Manufacturing  Milestones in Manufacturing History  Current Situation in Manufacturing  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 2 Content  Organizational Issues  Technology and Manufacturing  Milestones in Manufacturing History  Current Situation in Manufacturing  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 3 Topics  Introduction  Sustainable Manufacturing  Production Networks  Remanufacturing  Industrial Product-Service-Systems  Sustainable Business Models and Circular Economy  Factory Planning  Production Planning & Control I  Production Planning & Control II  Production Planning & Control III  Industry 4.0  Availability, Reliability and Maintenance Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 4 Dates (1/2) – Tentative Program Time Monday April 3rd Tuesday April 4th Wednesday April 5th Thursday April 6th Friday April 7th 09:00 - 10:30 h Introduction Practice Session Practice Session Sustainable Business Models and Circular Economy 10:30 - 12:00 h Sustainable Manufacturing Practice Session Practice Session Factory Planning 12:00 - 13:00 h Lunch Lunch Lunch 13:00 - 14:30 h Production Networks Remanufacturing No Class Industrial Product-ServiceSystems 14:30 - 16:00 h Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl No Class Holiday Lunch No Class Page 5 Dates (2/2) – Tentative Program Monday April 10th Tuesday April 11th Wednesday April 12th Thursday April 13th Friday April 14th Practice Session Production Planning & Control II Industry 4.0 Practice Session Practice Session 10:30 - 12:00 h Practice Session Production Planning & Control III Availability, Reliability and Maintenance Practice Session Practice Session 12:00 - 13:00 h Lunch Lunch Lunch Lunch Lunch 13:00 - 14:30 h Production Planning & Control I Practice Session Practice Session Exam QA No Class Practice Session Practice Session No Class Time 09:00 - 10:30 h 14:30 - 16:00 h Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl No Class Page 6 Content  Organizational Issues  Technology and Manufacturing  Milestones in Manufacturing History  Current Situation in Manufacturing  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 7 Global Economy Overview  Economics  social science and studies about production, distribution and consumption of goods and services  general overview of the economic structure: Economy Production Industry Public Households Service Industry Physical Product Industry e.g.: bank-, insurance-, trade-, culture-, health-, hotel and restaurant industry e.g.: handcraft-, farming-, manufacturing-, fishing industry Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Private Households main focus of MFP/FAB occasionally addressed in MFP/FAB Page 8 Global Economy Economic Sectors services, maintenance, cleaning www.artists4kids.com www.baumaschinenbilder.de Country Primary Sector Secondary Sector Tertiary Sector Germany Sweden Korea Albania 1.5% 2% 5.7% 41.8% 24.6% 12% 24.2% 11.4% 73.9% 86% 70.2% 46.8% www.telegraafhotel.com agriculture, forestry, fishing production industry including manufacturing, energy and process industry www.ecb.int Tertiary sector jpcindiansteel.nic.in Secondary sector www.simonsgp.com Primary sector % of total workforce (2014 est.) Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl main focus of MFP/FAB occasionally addressed in MFP/FAB Source: [CIA-15] Page 9 Production Main Categories Production Industry Process Industry Manufacturing generation of electrical, chemical and thermal energy production of materials production of geometrically defined products www.big10x.com www.big10x.com geothermal power plant Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl www.theautochannel.com Energy Industry oil refinery automotive assembly line main focus of MFP/FAB occasionally addressed in MFP/FAB Page 10 Technology General Classification  technology encompasses according to VDI 3780:  example – bio diesel  bio diesel substitutes fossil fuel, extracted  the set of use-oriented, artificial, concrete from (food) plants http://students.umf.maine.edu objects (artifacts or object systems),  the set of human actions and institutions from which object systems originate,  the set of human activities in which object systems are utilized.  Technology refers not only to concrete Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl  bio diesel competes against foodstuffs  food prices increase on the world market 120 700 100 600 80 500 60 400 40 300 20 200 US Dollars per Metric Ton production in million gallons object or systems but also to the conditions and impacts of their origin and utilization. U.S. biodiesel production Soybeans Price Source: [VDI-3780,EIA-13,NAS-14] Page 11 Criteria for Technological Value acc. to VDI Guideline 3780  personality development  e.g. freedom of action and creativity  societal quality  e.g. justice, solidarity and transparency  prosperity  e.g. satisfaction of demand, competitiveness  economy  e.g. profitability and efficiency  environmental quality  e.g. protection of landscapes and species, use of natural resources reduction of emissions  health  e.g. physical/psychological well-being, life expectancy  functionality  e.g. usefulness, feasibility and effectiveness.  safety  e.g. reduction of economical risk Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [VDI-3780] Page 12 http://putzlowitsch.de Value Meaning of Value  meaning of value  orientation for goods and actions, which is formed by normative expectation and reflected values 2€ coin, manufacturing cost: 0,13€/coin  forms of value  ethic/esthetic value: can be understood as usefulness/utilitarianism, http://www.gle niboutique.com felicitousness, desire/hedonism; moral concepts are inherent or results from education/experience; Kant‘s categorical imperative easy to communicate among global cultures  practical value: level of usefulness of things to serve a certain purpose or satisfy needs; expression of appreciation is geared to a subjective target system Cocco Ligator handbag for 588€ (online-shop), manufacturing cost 80-100€/bag http://www.wallpap erbase.com  exchange value: describes in a quantitative way the exchangeability manufacturing cost for one Space Shuttle > 400 Mio.€ with other goods, mostly mediate by money  economical value  economic index, reference for economic goods, e.g. price or cost  value of an asset deriving from its ability to generate income  expression of how important goods are to satisfy certain needs (configuration of preferences) Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 13 Value Evolution of Value – Genealogy of Axiology  changes in values for society with relation to manufacturing: Environmental Value environment Pragmatic Value  internal:  age structure of employees: older employees are replaced more often by younger ones society Economic Value  job demands: self-fulfillment Physiological Value individual Subjective Value Natural Value and good career opportunities are seen as integral part of life  external:  attitude towards environment: tendency to preserve the natural environment philosophy Absolut Value Objective Value  customers influence: purchase Meta-Knowledge Value time 350 B.C. 1500 A.D. 1600 1700 1800 1900 1950 pattern depends on wealth, income, taste, (mega-) trends 2000 differentiated view on value Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Ued-09] Page 14 Value Creation Process interpretation  Value creation describes activities to increase the value of a product, product parts or raw supply network, tier 2 auxiliary / secondary activities supply network, tier 1 focal activity or company distribution network, tier 1 distribution network, tier 2 customer resource materials. It can be divided into primary/main activities, causing direct increase in value, and secondary/auxiliary activities, causing indirect increase in value. company infrastructure human resources management research and development procurement inbound operations outbound marketing customer logistics (production) logistics and service distribution main / primary activities Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Por-00, Moe-06] Page 15 Factory  Prof. Spur (1994)  A factory can be understood as an industrial undertaking where employees work in parallel in a regular base (not at home) in an enclosed space and operate machines in a systematic order.  VDI 5200  A factory can be understood as the place where value creation happens by division of work using productive factors. Production includes all activities with operational efforts to create products.  That includes especially: designing, scheduling and planning of action, manufacturing, assembling, storing, handling, checking, planning and controlling of goods, as well as auxiliary processes like maintenance.  Virtual Factory  Global information (example)  Development in Berlin  Production in Lithuania  Installation in Nauen Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Source: [Spu-94, VDI-5200] Page 16 Factory as Value Creation Module  Process:  Product: ► assembly ► structure ► transport ► material ► inspection ► quality ► … ► …  Organization:  Equipment: ► logistics ► production program ► organizational structure ► … ► machine tools  Human: ► qualification/training ► motivation ► robots ► information systems ► … ► health ► … Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 17 Content  Organizational Issues  Technology and Manufacturing  Milestones in Manufacturing History  Current Situation in Manufacturing  Literature and References Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl Page 18 Historical Periods in Manufacturing >10,000 B.C. 10,000 B.C. 15th century hunting and gathering Neolithic revolution medieval handicraft transition to agriculture and settlement, trend to more available food and growing population allows specialized workers with more advanced tools (first division of work) animals provide food as well as raw material for basic tools Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl 18th/19th century industrialization shift from manual labor and draft animal based economy towards machine based manufacturing satisfaction of local needs by manual, specialized and to some extent mobile laborer (migratory laborer) 1930s 1990s rationalization digitalization digitalization of almost every aspect in manufacturing to accelerate gathering, processing and sharing of information as well as knowledge improve of efficiency and output, most times achieved by replacing manpower with machines Page 19 Technological Drivers in Manufacturing History >10,000 B.C. 10,000 B.C. 15th century hunting and gathering Neolithic revolution medieval handicraft Metal Processing, (8,000 B.C.) in the beginning gold, silver, cupper, from 4000 B.C. also iron letterpress printing (15th century), first flexible printing system enabled cheap spread of information Steam Engine (1780s), provided mechanical power for machine tools on industrial level Combustion Engine (1509), described by Leonardo da Vinci, 1862 first built and sold by Nikolaus Otto Technische Universität Berlin Institute for Machine Tools and Factory Management Univ.-Prof. Dr.-Ing. Holger Kohl 18th/19th century industrialization 1930s 1990s rationalization digitalization Electricity (1660), in 1866 Werner von Siemens developed electric engine Transistor (1947), foundation for computers and computerized controls Telephone (1876), long distance communication without significant delay Internet (1980s), enables global real-time data-exchange and supports international production activities/networks Page 20
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