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

由于安装时间依赖于顺序，公司必须接受高在制品水平和高分散的生产时间，以达到高产出率。基础研究项目的结果提供了一个模型，以量化建立周期的产出率增加和相关的生产时间变化作为在制品的函数。转移项目的目的是扩展具有重要的、实际相关的相互关系的模型，以便它们可以转移到运营生产计划和控制中，并在工业合作伙伴Robert Bosch GmbH中范例实施。研究的主要内容有：(1)设置周期对上下游仓库所需库存的影响，主要是由于分散的吞吐量时间及其对批量大小的影响。考虑工作站的安装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，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，安置家庭的需求往往分布不均。因此，在安装周期中更频繁地生产高产量的家庭比低产量的家庭更有意义。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，以确保模型的实际适用性。(3)目前，模型与企业的规划方式之间没有联系。因此，该模型在实践中难以发挥其潜力。因此，研究项目的目的是描述一种系统的方法来定义相关的规划参数，以便模型的发现导致实际的改进。该方法通过软件工具计算数学模型和规划参数来完成。(4)到目前为止，还没有文献记载的模型的实际应用，因此对企业来说，实施的感知风险很高。因此，研究项目的目的是与罗伯特博世有限公司在两个试点地区实施模型和规划方法，并将研究结果记录在指导方针中。(5)在实践中，在生产计划和控制中，没有一个通用的程序来考虑顺序相关的安装时间。因此，研究项目的目的是得出通用应用工具，并在与三家合作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.