Elements of Advanced Manufacturing Theory

Description

This book is the continuation of the textbook Lean Compendium – Introduction to Modern Manufacturing Theory. It extends the theory of mathematical modeling to batch & queue-based cyber-physical production systems. To facilitate learning, the book continues to develop a Cartesian-derived understanding of the system’s behavior by applying manufacturing-specific theorems, corollaries and lemmas. A law-based description enables to model production mathematically and understand upfront their dynamics in terms of WIP generation, lead-times, exit-rates, and on-time delivery performance. While simulation alone only allows to explore the optimum solution, the development of a theory allows to gain knowledge. This improves the learning of the “physics” of manufacturing systems and contributes to a solid production’s understanding and a clear and cognitive problem determination that leads to a thorough mental capture for mastering a systematic design of such highly complex systems. Foreword Prologue Contents 1 The Need for Manufacturing Theory 1.1 Introduction 1.2 Deficiencies and Limits of the Present Scholastic Approach in Manufacturing Theory 1.3 Elements of an Insight Gaining State of the Art Manufacturing Theory 1.4 The Value of Appropriate Simulation 1.5 Conclusion References 2 Basic Classification of Production Systems 2.1 Introduction 2.2 Some Basic Production Laws 2.3 Classification of Production Systems 2.3.1 B&Q Job-Shop Facilities 2.3.2 TFL Single Piece Flow-Shop Facilities 2.3.3 JIT Cellular Manufacturing Based on DBR Technique 2.3.4 Graph-Based CPPS 2.4 Gaining Insights and Comparing Performance 2.5 Summary and Outlook References 3 The Central Importance of the Bottleneck 3.1 Introduction 3.2 Linear Programming Aiming at Overall Optimization 3.3 Lean Manufacturing Aiming at Local Optimization 3.4 Synthesis of Both Approaches 3.5 Conclusion References 4 Elasticity, Lead-Time, and On-Time Delivery 4.1 Introduction 4.2 A Little Bit of Theory 4.3 The Paradoxon of the Mean 4.4 Developing Post-optimality Conditions to Respect OTD 4.4.1 The Case of a Non-ergodic Process with a Time-Bound Deterministic OR Above ER 4.4.2 The Case of a Stochastic OR with Stationary Ergodic Process Characteristic 4.4.3 Practical Application of Theoretic Findings 4.5 Summary References 5 Understanding the Advantage of Lean Pull JIT Versus Push B&Q 5.1 Introduction and Approach to the Problem 5.2 A Little Bit More Theory and Preliminary Assumptions 5.3 Developing Post-optimality Conditions for Complying with OTD 5.3.1 The Case of an Ergodic OR-Process with Deterministic Product-Mix 5.3.2 The Case of a Non-ergodic OR-Process with Deterministic Product-Mix 5.4 Outlook for Complex Manufacturing Systems 5.5 Conclusions References 6 Flexibility and the One-Off Product Challenge of CPPS 6.1 Introduction and General Approach 6.2 Preliminary Assumptions and Special Characteristics of CPPS to Be Considered 6.3 Additional Basic Theory Concepts Applied to Model CPPS 6.4 Understanding and Modeling Performance of CPPS 6.4.1 Product Characteristic, Order Frequency, and the Consequent Appropriate Design of the Manufacturing System 6.4.2 Workstation Load and Digital Twin-Based Simulation of Job Scheduling for OTD 6.4.3 Order Characteristic and Manufacturing Mode Define the “Physics” of the CPPS 6.5 Conclusions and Remarks References 7 Some Critical Considerations About Industry 4.0 7.1 Introduction 7.2 Today’ and Tomorrow’s Production Requirements 7.3 Basic Manufacturing Parameters 7.4 What Lean is All About 7.5 In a Nutshell: What Does Industry 4.0 Represent 7.6 Systems Performance and How Does Industry 4.0 Fit In 7.7 Conclusion References Epilogue Overview of Additional Manufacturing Laws and Principles