the production system development processzoomin.idt.mdh.se/course/kpp319/ht2015/lectures/lecture 5 -...
TRANSCRIPT
![Page 1: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/1.jpg)
The Production System Development ProcessSeptember 22, 2015
![Page 2: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/2.jpg)
A process
• Process • repetitive network • activities • uses information and resources• transform ‘object in’ to ‘object out’, • customer satisfaction
• Method• prescribed approach• Guides user• e.g. implement a new system”
Problem
Analysis of situation
Conceptual modelling
Evaluation of concepts
Evaluation of concepts
Decision
Solution
Setting of objectives
Decision
Detailed design
Wu, 1994
![Page 3: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/3.jpg)
Development as a process
• A process is as a road, starting with a need and ending in satisfaction
• The road (process) is used by different vehicles (projects)
![Page 4: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/4.jpg)
A process goes through departments
PROCESS
PROCESS
PROCESS
Department Department Department
Output Input
![Page 5: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/5.jpg)
Arguments for a process perspective on system development
• Overlook functional borders to solve problems• Improve ability to meet the customer in a comprehensive manner• Prerequisites for learning and development of knowledge
![Page 6: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/6.jpg)
Benefits of a holistic approach
● System designers - no essential information is left out.
● Project managers – what exists in the organization and what needs to be taken care of.
● Documentation – information and higher commitment to proposed solution.
● Production system – verification on time, reduce risk of installation, problems and disturbances before SOP.
● Information – Reuse for future development. Learn from past speed up design.
![Page 7: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/7.jpg)
Common activities in the design process
• Analysis
• Requirement specification
• Design or construction of
subsystems
• Integration of subsystems
into totality
• Evaluation and decision
Carin Rösiö JTH
Problem
Analysis of situation
Conceptual modelling
Evaluation of concepts
Evaluation of concepts
Decision
Solution
Sett ing of objectives
Decision
Detailed design
Chapter 5
![Page 8: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/8.jpg)
Practical approaches to system design
Carin Rösiö JTH
Problem
Analysis of situation
Conceptual modelling
Evaluation of concepts
Evaluation of alternatives
Decision
Solution
Setting of objectives
Decision
Detailed design
Problem
Analysis of situation
Conceptual modelling
Evaluation of concepts
Evaluation of alternatives
Decision
Solution
Setting of objectives
Decision
Detailed design
Problem
Analysis of situation
Conceptual modelling
Evaluation of concepts
Evaluation of alternatives
Decision
Solution
Setting of objectives
Decision
Detailed design
A: Concept-generating approach B: Concept-driven approach C: Supplier-driven approach
Chapter 5
![Page 9: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/9.jpg)
Production system development framework – a “mindset”
• Increased understanding
• Design is a double task:
• Planning of the design task
• The actual design task
• Also includes context and
the consequences
(performance)
Bellgran and Säfsten 2010
CO
NTE
XT A
ND
PER
FOR
MA
NC
E
PLANManagement
and controlStructured
methodology
Preparatory design
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-upRealizationand planning
![Page 10: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/10.jpg)
Contextual aspects
● Perspective and attitudes● Individuals, engagement, resource allocation to
production engineering and production development,short-term vs long-term perspective, focus on output, acomprehensive view, separating means and ends
● Company preconditions● Market requirements, production’s role, company culture,
management involvement
● Investment considerations● Reasons for investing, investment decisions
CO
NTE
XT A
ND
PER
FOR
MAN
CE
CO
NTE
XT A
ND
PER
FOR
MAN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatory design
Preparatory design
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT A
ND
PER
FOR
MAN
CE
PLAN
Management and control
Structured methodology
Preparatory design
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 11: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/11.jpg)
Performance
● Measures aligned with strategic intentions and competitive priorities
● Performance measurement systems
Flexibility
Dependability
Cost
Speed
Quality
Requirements of the market Production system
performance
CO
NTE
XT A
ND
PER
FOR
MAN
CE
CO
NTE
XT A
ND
PER
FOR
MAN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatory design
Preparatory design
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT A
ND
PER
FOR
MAN
CE
PLAN
Management and control
Structured methodology
Preparatory design
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 12: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/12.jpg)
Management and control of the project
● Allocation of resources to production● Daily operations vs long-term development,
production development vs product development
● Time perspective● Need varies, product life cycle vs production system
● Work team composition● Composition, internal/external personnel, project
management, information flow, communication
● Creativity and analytical ability● vs systematic, team composition
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatory design
Preparatory design
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatory design
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 13: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/13.jpg)
Structured methodology
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatory design
Preparatory design
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatory design
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
Bellgran and Säfsten 2010
![Page 14: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/14.jpg)
● Time limits puts pressure on schedule● Guarantee outcome● Facilitates coordination● Facilitates project management● Identification of areas for improvements● Long-term ability● Permit Control and Creativity ● …
Why a structured methodology?
![Page 15: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/15.jpg)
Preparatory design
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
CO
NTE
XT A
ND
PER
FOR
MA
NC
E
PLAN
Management and control
Structured way of working
Preparatory design
Design specification
DESIGN AND EVALUATE
IMPLEMENT
Start-up Realisation and planning
PREPARATORY DESIGN
Background studyPhase A Phase B
Pre-study
Requirement specification
Plan for production system development
![Page 16: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/16.jpg)
Preparatory design
● Background study – look backwards and inwards● Pre-study – look ahead/strategically/tactically
Backgroundstudy
Pre-study
•Analyze product and existing production system•Evaluate existing production system, own as well as others•Study existing documentation•Benchmark•Collect product data
•Analyze development and market potential •Identify interested parties demands, management’s targets/strategies, and interfaces towards surrounding environment•Identify internal/external production processes
Requirement specification
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 17: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/17.jpg)
Market Complex 1 9 8 7 6 5 4 3 2 1 Stable
Customers Existing/new (50/50 %) Existing (100 %)
Competitors’ new technology High None
Competitors’ similar technology High None
Regulations Several/tough Few/easy
Markets Several Few
Production Complex Stable
Volume size (volume/years) High Average
Volume variations High Stable
Planning Short-term Long-term
Fluctuations (time intervals) Irregular None
Product Complex Stable
Generation Mix of existing and new New
Product variations High Low
New technologies Several None
New branches/applications Several None
Product range expansions Several None
Organization Complex Stable
Competence Hard to find Easy to find
Management involvement High Low
Growth of organization High Low
Production sites Several Single
Complex scenarioEstimating a
probable scenario Stable scenario
![Page 18: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/18.jpg)
Design specification
● Design of conceptual production systems● Evaluation of conceptual production systems● Detailed design of chosen production system
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
Phase CDevelop conceptual production systems
DETAILED DESIGN
Evaluate conceptual production systems
Phase D
Phase EDetailed design of chosen
production system
System solution
![Page 19: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/19.jpg)
● Choose methods/tools and strategies
● Establish modules, sub-systems, operations, process
and layout, material supply, level of automation,
information, control and supervision, machinery and
equipment, work organization, work environment
● Handle complexity
● Iterate more solutions
● Communicate and find support for the solutions
Design of conceptual production systems
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 20: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/20.jpg)
● Choose method for evaluation
● Compare alternative solutions with regards to
requirements
● Calculate costs
● Summarize and communicate results from evaluation
● Make choice, communicate, and find support for
chosen solution
Evaluation of conceptual production system solutions C
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 21: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/21.jpg)
Detailed design of chosen system
● Proceed with chosen solution and formulate
detailed specification
● Design work place and work tasks
● Evaluate and find support for chosen solution
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 22: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/22.jpg)
● Build production system
● Plan start-up
Realisation and planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 23: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/23.jpg)
Realisation and planning
Planstart-up
Buildproduction
system
•Decide what will be bought/manufactured•Ask for tenders•Evaluate suppliers•Purchase equipment•Install•Verify
•Choose model for start-up•Prepare organization, appoint responsible•Plan training of personnel
Physical production system
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 24: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/24.jpg)
● Carry out production start-up● Follow plans from preceding phase
● Evaluate result● Evaluate final production system and development
process, feed-back results to process owner
Start-up of production system
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
EC
ON
TEX
T A
ND
PE
RFO
RM
AN
CE
PLANPLAN
Management and control
Management and control
Structured methodologyStructured
methodology
Preparatorydesign
Preparatorydesign
Detailed design
Detailed design
DESIGN AND EVALUATEDESIGN AND EVALUATE
IMPLEMENTIMPLEMENT
Start-up
Start-up
Realizationand planning
Realizationand planning
CO
NTE
XT
AN
D P
ER
FOR
MA
NC
E
PLAN
Management and control
Structured methodology
Preparatorydesign
Detailed design
DESIGN AND EVALUATE
IMPLEMENT
Start-up
Realizationand planning
![Page 25: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/25.jpg)
![Page 26: The Production System Development Processzoomin.idt.mdh.se/course/kpp319/HT2015/Lectures/Lecture 5 - Production... · Documentation – information and higher commitment to proposed](https://reader030.vdocument.in/reader030/viewer/2022040610/5ecf95ed3408f11f063484be/html5/thumbnails/26.jpg)
Production system design support
On optimal design process should tell:• What should be done and when• What techniques and tools will be needed at each stage• What information needs to be collected• What the output or result of each stage would be
(Love, 1996)
Important features of a process:• Simple to be widely used by engineers• Efficient with minimum trial-and-error effect• Versatile to be applicable in different situations• Prescriptive instead of descriptive to recommend the
soultions(Houshmand and Jamshidnezhad, 2006)