Design of matrix production systems for the personalized production of mechatronic machine modules

Abstract

Crisis-driven fluctuations of production volumes and the high number of variants in personalized production challenge production systems. To maintain their competitiveness production systems must be flexible, scalable and reconfigurable, and enable an efficient production of high volumes. Today’s prevalent mix-model production lines are dedicated to certain output quantities and a limited number of product variants. They are insufficient for personalized production in a turbulent business environment. This thesis provides a methodical system for designing matrix production systems. Matrix production systems consist of flexibly-linked process modules which are linked by a material flow only on demand. Each order pursues its own variant-specific path through the system. Due to their modular design, matrix production systems are able to integrate a variety of assembly and manufacturing processes to produce different product families in one system. The shared use of the process modules by a wide range of variants enables high utilization of investment-intensive production resources. A scaling of the output quantity or the integration of new variants is possible by functional adaptation or alteration of quantity of individual process modules with little impact on the overall system. The design method of the methodical system is based on the principles of Axiomatic Design. In a process-oriented approach, the process modules of a production system are first designed functionally and saved in a knowledge base for subsequent production system design projects. The process modules are specified for a specific functional scope according to the quantification of change barriers. To design a matrix production system suitable process modules are then selected for a specific production program and instantiated according to the capacity requirements of their functions in a flow-oriented layout. The methodical system specifies the design procedure and provides production system models and design criteria as decision support for production planners. It also specifies calculation rules for the selection of alternative solutions in the design process. Finally, an integrated evaluation method allows the comparison of alternative overall designs. The applicability and effectiveness of the methodical design system was validated with a production system design project at an electric motor manufacturer. This thesis thus makes a contribution to the competitive design of production systems.