Evaluation and Optimization of the Application of Lean Methods

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The aspired research project aims at developing a methodology to simulatively optimize and monetarily evaluate an enhanced manufacturing system performance by means of lean production methods. Due to an advanced yet company-specific development of integrated production systems on a factory level an orientation towards current implementation degrees as well as towards remaining potentials of lean production methods is contemplated. Analyzing and optimizing the impacts of a tailored combination of lean production methods on the analyzed manufacturing system it is aimed at utilizing simulation software. Besides the ability to forecast the interaction of lean production methods the abstraction level of a simulation-based analysis is low and therefor beneficial. In order to establish a monetary evaluation based on simulation results it is aimed at creating a framework capable to support management decisions proactively. It should be aligned to superordinate key performance indicators, such as lead times, production costs, and included quality costs. The aspired methodology should not only allow for a recurring dimensioning of the integrated production system with the help of lean production methods and an evaluation of the profitability of the implementation of an ideal state in reality, but also support a robustness analysis, e.g. in case of varying production volumes or a differing product mix, within the simulation model. Thereby it is possible to identify potential adaption times within a volatile environment. To deduct action plans for the adaption of the manufacturing system it is essential to compare and adjust effects of analyzed lean production methods and drivers of volatility.Underlying the research problem are the following relevant questions:- How to develop an integrated production system goal oriented and company specific based on the current implementation status?- How to evaluate the profitability of an application of an optimized lean production method combination?- When and how to adapt a manufacturing system e.g. due to varying production volumes or a differing production repeatedly?