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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