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In the context of production and factory planning, the expansion of the factory must already be taken into account during initial planning. This results in an increase in planning complexity, as the involved planners have to know the expansion stages of the factory in the different time periods and have to evaluate concept modifications across all time periods. This paper presents an idea for a planning tool, which takes expansion stages into consideration. The data model contains all relevant information to generate a simulation model of the factory in an almost automated way. The aim is to enable factory planners to quickly investigate concept changes with the help of simulation, for example, to identify bottlenecks.
Simulation Based Approach for Reconfiguration and Ramp up Scenario Analysis in Factory Planning
(2022)
Structural changes in production entail a potential economic risk for manufacturing companies. It is necessary to identify a suitable strategy for the reconfiguration process and to continue to meet the demand during the change in the factory structure and ramp-up phase. A simulation offers the possibility to analyze different ramp-up scenarios for the factory structure and to select a suitable concept for the reconfiguration process. A discrete event simulation approach is presented that can be used to evaluate variants of structural changes and serves as a basis for deciding on a reconfiguration strategy. This approach is demonstrated using a specific production step of a plant producing hydrogen electrolyzers, the results and generalized conclusions are discussed.
A factory has to adapt to a future production program and increasing volumes. The planning of new factories must therefore already take expansion stages and reconfigurations into account. This leads to an increase in the complexity of planning, as different variants have to be planned and put into a chronologically reasonable and cost-optimized sequence. A factory data model that covers expansion stages manages the planning data amount and reduces complexity. Based on existing models from the literature, a factory data model was developed and modeled in the Unified Modeling Language standard. The factory data model shows which classes are interdependent and how planning results are stored reusable for other variants. An example is used to explain the developed factory data model and highlighting its advantages. The aim is to enable factory planners to document variant sequences and expansion stages in a comprehensible way, which supports the interdisciplinarity of factory planning projects.