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

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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.