Model-based production planning and control for production areas with sequence-dependent setup times

由于设置时间依赖于序列，公司必须接受高的重复率水平和高度分散的吞吐量时间，以达到高输出速率。基础研究项目的结果提供了一个模型来量化设置周期的输出速率增加和相关的吞吐量随时间的变化。转移项目的目的是扩展模型，使其具有重要的、实际相关的相互关系，以便将其转移到运营生产计划和控制中，并在工业合作伙伴Robert Bosch GmbH中示范实施。研究项目的主要内容是：（1）设置周期影响上游和下游仓库的所需库存，主要是由于分散的吞吐时间及其对批量的影响。考虑工作站的设置周期，而不考虑其对库存的影响，是一个孤立和不完整的观点。因此，该研究项目的目的是模拟设置周期对股票的影响，以便公司能够做出明智的决策。(2)在实践中，对设置族的需求通常分布不均匀。因此，在设置周期中，生产大批量族比生产小批量族更有意义。因此，研究项目的目的是通过考虑高容量和低容量家庭来扩展模型，以确保模型的实用性。(3)目前，该模式与公司的规划方法之间没有联系。因此，很难在实践中发挥该模型的潜力。因此，该研究项目的目的是描述一个系统的方法来定义相关的规划参数，使模型的研究结果导致实际的改进。该方法通过软件工具完成数学模型和规划参数的计算。(4)到目前为止，还没有记录的模型的实际应用，所以实施的风险是非常高的公司。因此，该研究项目的目的是在两个试点地区与罗伯特博世有限公司一起实施模型和规划方法，并将研究结果记录在指南中。(5)实际上，在生产计划和控制中没有考虑顺序相关的准备时间的一般程序。因此，该研究项目的目的是获得一般的应用工具，并在与三家合作伙伴公司的研讨会上对其进行评估。

With sequence-dependent setup times, companies have to accept high WIP levels and highly scattering throughput times to reach a high output rate. The results of the basic research project provide a model to quantify both the output rate increase by setup cycles and associated throughput time variations as a function of WIP. The aim of the transfer project is to extend the models with important, practically relevant interrelations so they can be transferred to operational production planning and control as well as exemplarily implemented at the industrial partner Robert Bosch GmbH.The main contents of the research project are:(1) Setup cycles influence the required stock in upstream and downstream warehouses, mainly due to the scattering throughput times and their influence on lot sizes. Considering the workstation with setup cycles without taking its influence on stock into account, is an isolated and incomplete perspective. The aim of the research project is therefore to model the influence of setup cycles on stock so companies are able to make informed decisions.(2) In practice, the demand for the setup families is often unevenly distributed. Thus, it makes sense to produce high-volume families more often in the setup cycle than low-volume families. The aim of the research project is therefore to extend the model by considering high- and low-volume families to ensure the practical applicability of the models.(3) Currently, there is no link between the model and the planning approach of companies. Thus, it is difficult to exploit the model’s potential in practice. The aim of the research project is therefore to describe a systematic approach for the definition of relevant planning parameters so that the model’s findings lead to practical improvements. The approach is completed by software tools to calculate the mathematical models and planning parameters. (4) Up to now, there are no documented practical applications of the models so the perceived risk of implementation is very high for companies. The aim of the research project is therefore to implement the models and the planning approach with Robert Bosch GmbH in two pilot areas and to document the findings in a guideline.(5) In practice, there is no general procedure for taking sequence-dependent setup times into account in production planning and control. The aim of the research project is therefore to derive general application tools and to evaluate them in a workshop with three partner companies.