ADVANCED PRODUCTION

SYSTEM DESIGN

Prof. Dr. Dr.-Ing. Yilmaz Uygun

Chapter 03
Chapter 3
PROCESS ANALYSIS

Chapter 03 Advanced Production System Design - Process Analysis Page 2

 PROCESS DEFINITION

General „Operation to transform inputs in outputs“1

view
Customer
Customer order
[type, #, date,etc.]

Process
Input [manufacturing, data Output
[raw materials, data, etc.] processing, etc.] [product, information, etc.]

Production- „Sequence of tasks or operations with an internal (technological and

related organizational) connection to fulfil customer orders by involving
several work systems.“2

1
DIN EN ISO 9001:2005
Chapter 03 Advanced Production System Design - Process Analysis 2 REFA Page 3
2017
PROCESS CHARACTERISTICS

Controlled and step-wise procedure

Interaction of humans and machines

Creating parts, components, and products Process Chain

Purposeful transformation of material

Follow a sequence

Chapter 03 Advanced Production System Design - Process Analysis Page 4

 PROCESS MAPPING

Item

§ Graphical description and documentation of processes

§ Use of process modelling languages and symbols with well-defined notations that are
connected based on defined syntax
§ Help identifying necessary value-added and supporting processes to manufacture a product
§ Result: Process Map

Chapter 03 Advanced Production System Design - Process Analysis Page 5

PROCESS LEVELS

• 1st level material flow processes (company A → B)

Supply Chain
• Business processes (network order fulfillment)

• 2nd level material flow processes (system 1 → 2)

Facility
• Business processes (order fulfillment)

• 3rd level material flow processes (pre-assembly → final assembly)

• 4th level material flow processes (work station)
System
• Manufacturing processes
• Assembly processes

Chapter 03 Advanced Production System Design - Process Analysis Page 6

SAMPLE PROCESSES IN COMPANIES

Order Fulfillment Receiving

Purchasing Manufacturing Delivery
Business Processes Orders

Storing
Manuf. of Pre- Final
Manufacturing Raw
Parts
Transport.
assembly
Transp. Coating Transp.
assembly
Transp.
Materials

Production
Scheduling Order Release Processing Monitoting
Control

Manufacturing System Product Process Resource Layout

Design Planning Planning Planning Planning

Production Program Requirements Purchasing Manufacturing

Planning Management Management Management Managrment

Chapter 03 Advanced Production System Design - Process Analysis Page 7

PROCESS VS. FUNCTIONAL VIEW

Order 1

Order 2

Order 3 process orientation

Order 4
• Less lead time
Order n • Higher due date reliability
• Less inventory
• Process-based calculation
Distri- • Higher product and process quality
Sales Purchasing Production • Less hierarchies
bution

functional

• Less operation times

• High capacity utilization
• Higher product quality
• Interfaces
• Higher inventory

Chapter 03 Advanced Production System Design - Process Analysis Page 8

 PROCESS TYPES

Value-added Supporting
planned planned

CV CV
extend
RC RC

Processing Transportation
Assembly Storing

CV = Customer Value
Non-Value Added Value-destructive
RC = Resource Consumption
unplanned unplanned

identify CV CV

and RC RC
eliminate
Buffering Scrap
Searching parts Failures

Chapter 03 Advanced Production System Design - Process Analysis Page 9

MAIN DOCUMENT: STANDARD ROUTE SHEET

Chapter 03 Advanced Production System Design - Process Analysis Page 10

CLUSTERING

Chapter 03 Advanced Production System Design - Process Analysis Page 11

CLUSTERED ROUTE SHEET

Chapter 03 Advanced Production System Design - Process Analysis Page 12

 MATERIAL FLOW MATRIX
TEILENR. 51540002 GÜLTIG AB 12.01.01
TEILENR. 51540002 GÜLTIG AB 12.01.01
TEILENR. KUGELGELZAPFEN
BENENNUNG: 51540002 GÜLTIG AB400
LOSGRÖSSE 12.01.01
TEILENR.
Item-ID
BENENNUNG: 56004
51540002
KUGELGELZAPFEN Valid
GÜLTIG
LOSGRÖSSE as AB
of 400
01/12/17
12.01.01
BENENNUNG: KUGELGELZAPFEN LOSGRÖSSE 400
Item:
BENENNUNG:
Ball Studs
MATERIALNR. KUGELGELZAPFEN
1275217 LOT
LOSGRÖSSE
Size 400 400
Route Sheets

MATERIALNR. 1275217
MATERIALNR.
BENENNUNG: 1275217
MATERIALRUNDSTAHL
MATERIALNR.
BENENNUNG: #RUNDSTAHL
127521715 CR MO S 74
15 CR MO S 74
BENENNUNG: RUNDSTAHL 15 CR MO S 74
POS Material:
BENENNUNG:
KST Round Steel
ARB.PLATZ 15
RUNDSTAHL CR MO S 74
15 CR
WZ/VOR MO S 74
ARBEITSGANGBESCHR. TU/s TR/min
POS KST ARB.PLATZ WZ/VOR ARBEITSGANGBESCHR. TU/s TR/min
010POS 217KST 4236
ARB.PLATZ WZ/VORABLÄNGEN 122mm
ARBEITSGANGBESCHR. 144TU/s 25TR/min
010POS 217ST
KST Work
4236 Station Tool
ARB.PLATZ Process
WZ/VORABLÄNGEN Step
ARBEITSGANGBESCHR.
122mm Te/s
144TU/s T s/min
TR/min
25
020010 334217 56274236 GT548 PLANDREHEN
ABLÄNGEN 122mm 070144 40 25
020010 334217 56274236 GT548 Cutting
ABLÄNGEN
PLANDREHENto 122mm
122mm 070144 40 25
030020 334334 56285627 K65Z12
GT548 KUGELGREHEN
PLANDREHEN 056070 60 40
030020 334334 56285627 GT548 KUGELGREHEN
K65Z12 Turning
PLANDREHEN 056070 60 40
040030 334334 56325628 V21097
K65Z12 GEWINDESCHNEIDEN
KUGELGREHEN 034056 30 60
040030 334334/5
334 56325628 K65Z12 GEWINDESCHNEIDEN
V21097 Sphere
KUGELGREHEN
Turning 034056 30 60
050040 334334 53485632 V21097 RISSPRÜFUNG
GEWINDESCHNEIDEN 012034 10 30
050040 334352
334 53485632 V21097 RISSPRÜFUNG
Thread
GEWINDESCHNEIDEN
Cutting 012034 10 30
060050 352334 43805348 W00392 WALZENRISSPRÜFUNG 060012 120 10
060050 352328
334 43805348 Crack
RISSPRÜFUNG
W00392 WALZEN Test 060012 120 10
070060 988352 98264380 W00392SCHLUSSPRÜFUNG
WALZEN 004060 10120

334/5

988
590
211

328

348
217

352
334

452
585
586
070060 988988
352 98264380 W00392SCHLUSSPRÜFUNG
Rolling
WALZEN 004060 10120

to
080070 348988 10179826 ABLIEFERN AN
SCHLUSSPRÜFUNGLAGER 25 004 10
080070 348348
988 10179826 Quality
SCHLUSSPRÜFUNG
ABLIEFERN Check
AN LAGER 25 004 10
080 348 1017 ABLIEFERN AN LAGER 25 from
080 211
348 1017 Storing
ABLIEFERN AN LAGER 25
211 22.7 26
From
From ToTo Quantity
Quantity
Annual Output From To Quantity 217 22.7

217
217
217 334
334
334 22,700
22,700
22,700 328 8.3
Jahr:
FY 2018
2001
334
334/5 8.3 14.4
Artikel
Item Stück
Quantity 334
334
334 334/5
334/5
334/5 22,700
22,700
22,700 348 8 16.2
56004 22,700
3.000 334/5 352 14,400
56006 2.500
2,500
334/5
334/5 352
352 14,400
14,400 352 14.4

54023 8.000
8,000 334/5
334/5
334/5 328
328
328 8,300
8,300
8,300 334 22.7
57802 4.000
4,000
352 988 14,400 452
57902 4.000
4,000 352
352 988
988 14,400
14,400
54566 1.200
1,200
585 10.2
328
328
328 988
988
988 8,300
8,300
8,300
..... ...... 586 25.6

988
988
988 348
348
348 8,000
8,000
8,000 590 15.4

988 211 14,700 988 14.7 8

988
988 211
211 14,700
14,700
348
348
348 211
211
211 8,000
8,000
8,000 Material Flow Matrix [in 1,000]
Material Flow Table [# of items]
Chapter 03 Advanced Production System Design - Process Analysis Page 13
 TRANSPORTATION MATRIX

334/5

988
590

334/5
211

328

348
217

352
334

452
585
586

988
590
211

328

348
217

352
334

452
585
586
to

to
from from
211 22.7 26
211 113.5 130
217 22.7
217 113.5
328 8.3

Transportation Units
328 41.5

Consideration of
334
334/5 8.3 14.4
334
334/5 41.5 72

348 8 16.2
348 40 81

[200]
352 14.4
352 72
334 22.7
334 113.5
452 452
585 10.2
585 51
586 25.6
586 128
590 15.4
590 77
988 14.7 8
988 73.5 40
8

Material Flow Matrix [in 1,000] Transportation Matrix [TU]

Chapter 03 Advanced Production System Design - Process Analysis Page 14

TRANSPORTATION INTENSITY MATRIX

334/5

452
211
217
328

348
352

585
586

988
590
334
to
from
211 2.84 6,5
217 4.54
328 4.15
334/5 6.12
348 2.4 2.43
352 3.96
334 9.08
452
585 2.04
586 2.56
590 4.62
988 3.68 1.6

Transportation Intensity Matrix

nach

334/5

590
348
217
328
334

352

585
586
211

427
452

988
334
von [1,000m x TU]
211 25 50

217 40 40

328 100

334/5
334 85

348 60 30

352 55 55
334
427 80 80
20m

452 30
15m
585 40

586 20

590 60

988 50 20

Facility Layout Distance Matrix [m]

Chapter 03 Advanced Production System Design - Process Analysis Page 15

SANKEY DIAGRAM FOR PROCESS FLOW

20m
15m

586 585 427 452 988

348

217 334 352

211 590
328

20m
15m

Chapter 03 Advanced Production System Design - Process Analysis Page 16

OPTIMIZATION OF TRANSPORTATION MATRICES

to

to
from from

Chapter 03 Advanced Production System Design - Process Analysis Page 17

DESIGN WITH SANKEY ARROWS
Transportation Matrix Transportation Matrix`

nach

5628
5627

5632
5348
5348
5632

5627
5628
to

to

...
...

...
...
from
von
from
... 12 ... 12

5632 2,6 5627 7 5

5628 5628 4,4

20m
4,4

5348 8 15m 5632 2,6

5627 7 5 5348 8

... ...
in 1,000
in 1,000

12.000 5627
7.000 12.000 5627 7.000
5kkk 5628 5uuu
5xxx 5uuu 5544

5.000
4.400 5628 5kkk

4.400
5xxx
5544

5.000

5ddd
5632 5348
5348

2.600
5ddd 2.600 5632
8.000 8.000
Chapter 03 Advanced Production System Design - Process Analysis Page 18
EXAMPLE: WIRE ROPE HOIST

Order Fulfillment

Management Processes

Information Processes

Material Flow Systems

Purchasing Production Distribution

Chapter 03 Advanced Production System Design - Process Analysis Page 19

EXAMPLE: WIRE ROPE HOIST
Order Fulfillment

Management Processes

Information Processes

Assembly
Welding
Carrier

Materialflusssysteme
Assembly
Pressing Under
Be- carriage
schaffung Produktion Distribution
Final
Assembly

Assembly Assembly
Washing
Hoist Gear Lift Drive

Assembly Assembly
Drive Drive System

Control

Chapter 03 Advanced Production System Design - Process Analysis Page 20

DRIVE SHAFT MANUFACTURING

Chapter 03 Advanced Production System Design - Process Analysis Page 21

 SHAFT MANUFACTURING

D E

A B

A B C D E

Cutting Turning Milling Annealing Grinding

Chapter 03 Advanced Production System Design - Process Analysis Page 22

 FLANGE MANUFACTURING
F

G H

F G H I

Thread
Sawing Drilling Turning
Cutting

Chapter 03 Advanced Production System Design - Process Analysis Page 23

ASSEMBLY OF THE FLANGE

M L

J K

J K L M

Temp.
Cooling Heating Joining
Balance

Chapter 03 Advanced Production System Design - Process Analysis Page 24

CHALLENGES

1. Map the processes of the given manufacturing system with the 3 clusters

2. Develop a Transportation Intensity Matrix for this manufacturing system stepwise by

generating/using the following means
§ Material Flow Table & Matrix (spreadsheet S 8)
§ Transportation Matrix (spreadsheet S 9)
§ Distance Matrix (spreadsheet S 10)

Chapter 03 Advanced Production System Design - Process Analysis Page 25

CHALLENGE 1
grinding
Cluster 1 milling
sawing milling

sawing milling drilling milling

sawing drilling

Cluster 2
milling grinding milling

storing sawing turning drilling storing

Cluster 3
turning milling grinding sawing tempering

sawing milling drilling milling

turning

milling milling milling grinding tempering

turning drilling sawing

Chapter 03 Advanced Production System Design - Process Analysis Page 26

THANK YOU!