Fig 2 - uploaded by Wolfgang Grenzfurtner
Content may be subject to copyright.
Capacity planning with flexible production lines and personnel planning. Work order and employees can be scheduled on the individual lines according to demand and requirements.
Source publication
This paper deals with new opportunities of Industry 4.0 applications for capacity planning on mixed-model assembly lines for industrialized housebuilding. We formulate a linear programming model for capacity planning on several parallel production lines and show how this model is fed with accurate data. The solution of the linear program in turn ge...
Context in source publication
Context 1
... In addition, the influence of personnel scheduling is also examined. Here, the employees are deployed throughout the entire production according to their qualifications, in contrast to the current situation where they can change within a line. It is assumed that this will further increase the maximum possible output. These next steps are shown in Fig. 2 In addition, smaller and larger line restructurings are being investigated that can be carried out with or without investment in plant and machinery. All these measures are tested and validated with the optimization model, the bottlenecks are evaluated and appropriate measures are taken to optimize the production output as much as ...
Similar publications
Objectives
Despite the fact that team manual handling is common in different working environments, the previous studies in this regard, particularly those with a physiological approach are quite limited. The present study is an attempt to model the heart rate (HR) of individual and team manual handling with one hand.
Methods
Twenty-five young men...
Citations
... The work by Grenzfurtner and Gronalt (2020) in the field of industrialised house building examines how the knowledge of the employees can be used in continuous improvement programmes and what needs to be adapted to facilitate this integration. Huka, Grenzfurtner, Zauner, and Gronalt (2021) present an application for capacity planning on mixed-model assembly lines. It is shown by means of real-time data input how the determined production times become increasingly precise and thus solutions of this model can be continuously improved. ...
... As shown in the paper by Huka et al. (2021), we use the increasingly precise recorded production times and analyse the potential for improvement in production planning for MMMAL. The identified research gap covers multiple aspects. ...
... The model of Huka et al. (2021) facilitates the assessment of the current situation and the scenario calculations. The input parameters were collected using documents and business processes from the industrial partner, data collection and time measurements conducted by the researchers in the plant, data comparisons with the ERP system and workshops with production planning staff. ...
This paper analyses the production planning for the multi mixed-model assembly lines (MMMAL) for building elements prefabrication. Industrialised housebuilding (IHB) prefabrication plants struggle with increasing the productivity of existing prefabrication equipment through the application of traditional planning methods. This research aims to apply a linear programming model to solve this planning problem. To test the model a wall element prefabrication plant with three distinct lines formed the test ground. Three scenarios are defined and evaluated to map job and product rotation, this is to generate more flexibility and enable better response to bottlenecks. The model is implemented to determine the optimal solution for each scenario and the experiments were done with real production data. Firstly, the formation of floater groups to improve worker scheduling and, secondly, the product rotation, is expanded to circumvent production bottlenecks. In a third scenario, the previous two are combined. The linear optimisation model allowed to improve the production planning for MMMAL by increasing the output by more than 50% compared to the initial situation. Additionally, more than 70% skilled worker resources can be saved. The contribution of this paper is that it shows the improvement potential in production planning for MMMAL through the application of an optimisation model using a combination of job and product rotation.
... Além disso, existem situações em que as variáveis podem assumir valores reais, caracterizando a Programação Linear Inteira Mista (PLIM) (Vanderbei, 2020). Como exemplos da PLIM, podem ser citados: a aplicação para os limites de tempo na cadeia de suprimentos, o suporte ao planejamento da capacidade produtiva, o sequenciamento de produtos e quantidade de pessoal em linhas de montagem paralelas (Gamrath et al., 2019;Huka et al., 2021). ...
Vários problemas do mundo real podem ser modelados com o uso da Programação Linear, dentre eles, os temas voltados para a sua aplicação na indústria. Neste contexto, este estudo tem como objetivo identificar as aplicações da Programação Linear na Indústria e suas conexões com os Objetivos de Desenvolvimento Sustentável (ODS). A metodologia utilizada é uma análise sistemática e bibliométrica de artigos científicos indexados na base de dados Scopus, considerando a aplicação da programação linear na indústria. Também foram pesquisados os desafios, aspectos positivos e negativos, perspectivas e oportunidades no uso da programação linear e a sua conexão com os objetivos de desenvolvimento sustentável. O estudo foi composto pela análise de 136 artigos, referente ao período de 2000 até julho de 2023. Foram gerados mapas temáticos com o uso do Bibliometrix, para orientar as discussões da pesquisa. Constata-se que é possível a aplicação da formulação de problemas da programação linear em várias atividades na indústria, nos assuntos de mão de obra, redução de estoque e atendimento da demanda. O maior desafio está na formulação de problemas que abrangem os aspectos da sustentabilidade, principalmente no uso da energia renovável e o impacto ambiental, que também são temas-motores neste campo de pesquisa. Palavras-chave: Sustentabilidade. Impacto ambiental. Agenda 2030. Eficiência Energética. Programação linear.
... Task assignment was studied in various applications. Cetin et al. (2020) and Huka et al. (2021) studied personnel task assignment problems. They developed a multi-objective mathematical model to assign the number of transactions to employees in a bank by considering this problem as GAP. ...
... GAMS was used as a solver for all the test problems. Huka et al. (2021) ...
... The work by Grenzfurtner and Gronalt (2020) in the field of industrialised house building examines how the knowledge of the employees can be used in continuous improvement programmes and what needs to be adapted to facilitate this integration. Huka et al. (2021) present an application for capacity planning on mixed-model assembly lines. It is shown by means of real-time data input how the determined production times become increasingly precise and thus solutions of this model can be continuously improved. ...
... As shown in the paper by Huka et al. (2021), we use the increasingly precise recorded production times and analyse the potential for improvement in production planning for MMMAL. Compared to the previous work in MMMAL, the focus here is not on the simultaneous sequencing of orders on the different production lines, but on the allocation of orders to the different lines and the scheduling of the available personnel at the individual workstations. ...
... The model of Huka et al. (2021) facilitates the assessment of the current situation and the scenario calculations. The notation used is listed in Table 2. ...
... Statistics show that at least three people die in construction accidents every day in our country. However, in the UK, where the prefabrication rate is as high as 70%, at least one construction worker dies every week on average [3]. Not only that, the environmental pollution, the exhaustion of energy, and the serious haze are also worth our concern. ...
In order to take a scientific risk control strategy to reduce the safety risk of construction projects, a construction safety risk decision-making method based on particle swarm optimization algorithm was proposed. Through the analysis of prefabricated building construction safety risk factors, the combination of the Markov Chain and Bayesian networks method was used to estimate the probability of risk factors. The relationship between the various risk factors was described by conditional probability, and a safety risk loss-control investment double objective optimization model was built. The corresponding algorithm was designed and the R language programming was used to solve the problem. The experimental results showed that by taking a high degree of control over the risk factors of the investment strategy, when the constraint cost was RMB 200,000, the global optimal risk loss and the global optimal control cost were RMB 1,400,500 and 19,600, respectively. When the constraint cost was 280,000 yuan, the global optimal risk loss and global optimal control cost were 1.046 million yuan and 278.5 million yuan, respectively. When the constraint cost was 320,000 yuan, the global optimal risk loss and global optimal control cost were 910,100 yuan and 317,300, yuan respectively. It was concluded that, considering the risk correlation optimization model, a reasonable allocation strategy was adopted, combined with the actual situation, which performed a promoting function in improving the assembly building construction safety risk decision-making.
... Searching for current literature specifically about the functions process and capacity planning suggests a high availability of Industry 4.0 approaches in these areas (e.g. Trstenjaka & Cosic, 2017;Chien, Dou & Fu, 2018;Huka, Grenzfurtner, Zauner & Gronalt, 2021). In contrast, lot-sizing and production order scheduling have not been related to Industry 4.0 approaches in the current literature. ...
Purpose: Industry 4.0 technologies influence how production is planned, scheduled, and controlled. In literature, different classifications of the tasks and functions of production planning and control (PPC) exist, of which one is the German Aachen PPC model. This research aims to identify and classify current Industry 4.0 approaches for planning and controlling production processes and to reveal researched and unexplored areas of the model.
Design/methodology/approach: In an exploratory literature review, we review and classify 48 publications on a full-text basis with the Aachen PPC model's tasks and functions. Two cluster analyses reveal researched and unexplored tasks and functions of the Aachen PPC model. Additionally, we give a summary of each reviewed publication.
Findings: We propose a cyber-physical PPC architecture, which incorporates current Industry 4.0 technologies, current optimization methods, optimization objectives, and disturbances relevant for realizing a PPC system in a smart factory. Current approaches focus on the in-house PPC, particularly on the control using real-time information from the shop floor. We propose future research directions for the unexplored tasks and functions of the Aachen PPC model.
Research limitations/implications: The selection of search terms and the texts' interpretation is based on an individual assessment. The revelation of unexplored tasks and functions of the Aachen PPC model might have a different outcome if the search term combination is parameterized differently.
Originality/value: Using the Aachen PPC model, which holistically models PPC, the findings give comprehensive insights into the current advances of tools, methods, and challenges relevant to planning and controlling production processes under Industry 4.0.
... The latest capacity planning solutions take advantage of the opportunities offered by Industry 4.0 application. The capacity planning model for prefabricated housebuilding elements uses real-time data entry to improve assembly line performance planning [20]. This approach develops short-term capacity equalization in make-to-order production systems [21]. ...
The article presents the application of the original methodology to support tactical capacity planning in a medium-sized manufacturing company. Its essence is to support medium-term decisions regarding the development of the production system through economic assessment of potential change scenarios. It has been assumed that the developed methodology should be adapted to small and medium-sized enterprises (SMEs). Due to their flexibility, they usually have limited time for decision-making, and due to limited financial resources, they rely on internal competencies. The proposed approach that does not require mastery of mathematical modelling but allows streamlining capacity planning decisions. It uses the reasoning of throughput accounting (TA) supported by data obtained based on discrete event simulation (DES). Using these related tools in the design and analysis of change scenarios, make it possible for SME managers to make a rational decision regarding the development of the production system. Case studies conducted in a roof window manufacturing company showed the methodology. The application example presented in the article includes seven change scenarios analyzed based on computer simulations by the software Tecnomatix Plant Simulation. The implementation of the approach under real conditions has shown that a rational decision-making process is possible over time scale and with the resources available to SMEs for this type of decision.
