Abstract
Due to a growing number of product variants, shorter lead times, and global supply chains, planning and launching production systems is becoming increasingly important. Therefore, managing the period of production ramp-up becomes a competitive advantage. To handle the increasing complexity and uncertainty in this special phase, data availability is necessary in terms of efficient decision making. However, in this early phase of the product and production system lifecycle, data quantity and quality are not guaranteed. This is due to the degree of novelty of processes, technologies and human behaviors in this special phase. In this paper it will be analyzed that selected data from the factory planning phase as well as the factory operation phase needs to be jointly processed by ramp-up involved personnel as value adding information. Finally, the presented use case, as well as the derived data management approach, will help companies to better manage production ramp-ups in the future.
Highlights
Due to shorter product lifecycles and growing range of product varieties, the ramp-up phase, which is the transition from factory planning to factory operation phase, becomes increasingly important [1]
The digital factory approach supports production planning departments with a “network of digital models, methods and tools (...), which are integrated by a consistent data management.”
In the instable and critical production ramp-up phase it can be beneficial in terms of time-to-market reduction to manage high quality planning data from the factory planning phase as well as real operating data bidirectional [4]
Summary
Due to shorter product lifecycles and growing range of product varieties, the ramp-up phase, which is the transition from factory planning to factory operation phase, becomes increasingly important [1]. The digital factory approach supports production planning departments with a “network of digital models, methods and tools (...), which are integrated by a consistent data management.” [2] In the operating phase, the interconnection of people, products and other resources in form of cyber-physical production systems focuses on collecting, analyzing and providing real-time data in order to improve value-added processes [3]. In the instable and critical production ramp-up phase it can be beneficial in terms of time-to-market reduction to manage high quality planning data from the factory planning phase as well as real operating data bidirectional [4]. In general one can say that Industrie 4.0 leads to real-time data availability (digital shadow), which, if integrated in the digital twin by a consistent data management, results in highest planning accuracy in the digital factory as well as the factory operations [8]. In order to minimize this gap and secure an integrated bidirectional data management in the ramp-up phase it is necessary to define two different levers that are described in the following: 1. Lever 1 – Exploiting digital factory planning tools: What tools and methods from the digital factory can be used in order to process and provide high qualitative planning data in the ramp-up phase?
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