DE102016103771A1 - Method of producing a product with integrated planning and direct integrated control - Google Patents

Abstract

There is provided in various embodiments a method of manufacturing a product, wherein the product is a functional unit composed of at least two parts, each of which is located in a separate location, the method comprising: at least one logistics process, in which a part is transported from its location to the place of need; and at least one manufacturing process in which the part is assembled with at least one further part at the demand location, the process being planned and / or simulated in its entirety before and during its execution in a first electronic data processing program and / or directly controlled by a second electronic data processing program wherein the direct control is with respect to a group of production factors comprising employees and / or resources and / or material.

Description

The invention relates to a method for producing a product, for example a motor vehicle, with an integrated planning and a direct holistic control of the overall manufacturing process.

In the industrial production of products, logistics and manufacturing processes are mainly planned in separate areas and are also operationally controlled in different areas.

The former are planned in the course of logistics planning and the latter in the course of production planning. They are also operationally controlled by different departments, such as the former in operational logistics and the latter in corresponding production areas.

This has historically shown that the methods, processes and systems used in manufacturing and logistics - IT systems and systems engineering - differ. The relevance of this fact becomes clear when you realize that up to 500 different IT systems are needed today in a modern automotive plant to control production and logistics.

An example of different methods in manufacturing and logistics is the recording and evaluation of work. In manufacturing, this is done by means of time-management methods by industrial engineering, in logistics, this method is usually not used. Another example is the different plant technology and IT systems for controlling the picking processes in production and logistics.

At the same time, the requirements for a closer process-based integration of production and logistics are increasing: in the future, more and more material will be delivered just-in-time (JIT, ie synchronized to demand) or just-in-sequence (JIS, ie synchronized in sequence), in order to be able to minimize the storage space despite the increasing number of variants. A goal of the logistics is to be able to control each material in the future as JIT / JIS part and thus without local storage. In the future, logistics will work synchronously with the production cycle and must adapt to it. Another trend is the development of the delivered material from the individual part to more complex submodules. As a result, production activities and, as a result, added value are shifted from the production line to the logistics chain, which means that logistics assumes responsibility for the construction and fault-free operation of entire modules.

Since today logistics and manufacturing processes in many different and only partially interconnected IT systems are planned and operationally controlled, the digital overall picture of the manufacturing process is missing. This means that no comprehensive, global optimizations involving all relevant processes are possible.

The aim of the invention presented here is to better harmonize the individual processes of the production of products and the processes of logistics and to make the overall process (i.e., the overall manufacturing process) more efficient.

The solution of the task is based on a standardization of the methods and processes from manufacturing and logistics in a common planning tool in order to be able to plan, optimize and simulate the processes holistically.

An example of the unification of the methods is today's modeling of a montage, which is methodically carried out over a sequence of stations where work is done. Similarly, the logistics process can be modeled: Logistical stations are then, for example, goods receiving, picking stations or transport routes. Another example of this is the time-based methods, which can easily be applied to logistics within an integrated planning tool.

Examples of the standardization of processes are the procedural implementation of the application of time-management methods (who, how, what, when) or the transfer of quality processes from production to logistics.

Examples of the standardization of systems are pick-by-light systems, pick-by-voice systems and the like, both in production and as well used in logistics and that are still very different today.

Based on the joint planning tool, a common operational process control system for production and logistics is used to control the manufacturing process holistically. The operational process control system is based on real-time data from the entire process chain, i. It covers all production and logistics processes, from the supplier to the material supply at the place of requirement.

The planning tool and the process control system together form the so-called production process platform. The production process platform represents the overall digital image of everyone Processes on the basis of which a holistic process optimization is made possible. These optimizations can be done manually or (partially) automatically. Manual optimizations are much more efficient and easier to carry out today because of the complete transparency of the overall process. (Partial) automated optimizations can be applied to the overall process for the first time using AI or deep learning methods (ie, machine learning using algorithms that mimic human learning) based on real-time data.

The joint and holistic planning of production and logistics processes in a planning tool shortens the planning times by a factor of 2 to 4 and enables more efficient, because optimally coordinated process sequences (also factor 2 to 4).

The operational process control system, based on real-time data, enables a holistic control of all processes to achieve a global overall optimum.

Optimizations in the planning tool and in the process control system, possibly based on real-time data, allow, for example, for process deviations (eg quality problems, errors, failures of machines, congestion in the material supply, etc.) to react very quickly on the basis of well-founded, if necessary, already Results of pre-simulated decision options.

In summary, the individual processes of industrial production of products, including the logistics process, in the context of the overall process, can be better coordinated and optimized in terms of planning and control - even in real time - in order to achieve a global optimum from the perspective of the overall process.

Preferably, planning and operational control can be implemented in just one tool, in which logistics and manufacturing processes can be coordinated together. This has many advantages, which can ultimately solve a variety of problems. For example, it is no longer possible to use outdated schedules in a factory that do not reflect the actual operations in the manufacturing and / or logistics operations (for example, lack of communication between the divisions). Furthermore, starting from a current state (operating state), a forward viewing can be performed at any time (simulation of "what if" scenarios). In addition, the uniform planning, simulation and control tool can be used to intervene at every single point in the overall process, without causing inconsistencies between processes that are controlled separately from one another and yet distant, which in the worst case can lead to production stagnation. The effects of any intervention in the overall production can be simulated in advance in the planning tool with all the effects and checked for compatibility with the existing overall process. In this way, a total optimum for the overall process can be calculated and regulated in real time.

In various embodiments herein, there is provided a method of manufacturing a product, wherein the product is a functional unit composed of at least two parts, each of which is located in a separate location. The method comprises at least one logistics process, in which a part is transported from its location to the demand site, and at least one manufacturing process, in which the part is assembled with at least one further part at the demand location. In this case, the method is planned and / or simulated in its entirety before and during its execution in a first electronic data processing program (hereinafter: first program) and / or controlled by a second electronic data processing program (hereinafter referred to as a second program) of production factors, which has employees and / or resources and / or material.

By means of the overall production process considered in the context of the invention, any functional units can be produced as products. These can be mechanically and electronically complex products such as motor vehicles, computers or mobile devices, or rather simpler products such as hairdryers or bicycles. The process is particularly suitable for products that are manufactured industrially in large quantities. However, all products that can be produced by the method have in common that they are composed in the context of the manufacturing process of at least two parts, wherein at least one of the two parts can already form an assembled product. In this case, each of the at least two parts that are assembled to produce the product, in a separate location. By this it is meant superficially that each of the at least two parts has to be transported to a place of need by means of a logistical process. This may be the logistical transport of the part from outside the factory (manufacturing plant) to the factory site or also the logistical transport of the part on the factory premises, for example from a warehouse to the site of need. At the If required, the part is processed, for example, by being assembled or deformed with another part. The demand location can therefore be a processing or assembly location from the perspective of the one part. Of course, it is conceivable that each of the parts is previously processed individually in the context of manufacturing, for example, painted, deformed or changed by attaching other parts. At any stage in the manufacturing process, however, the considered part is assembled at the convenience store with at least one other part. As a concrete example, here is a transmission called, which is first supplied by a supplier to a factory and then transported to the place of need, where it is attached to a corresponding vehicle.

According to the invention, the method is planned in its entirety before and during its execution in a first program, that is to say a correspondingly configured software program, and optionally also preferably simulated. Within the first program, the modeling of logistics and manufacturing processes follows in a consistent manner. The first program is set up in such a way that it can be used to map the overall process for the purpose of planning and / or preferably to simulate it. The first program is able to consider all factors of production and their influence on each other, regardless of whether they are classically associated with logistics or manufacturing. In other words, by means of the first program, the entire process can be mapped on an abstract planning level without fundamentally distinguishing whether a process or method is to be assigned to logistics or production. By means of the first program, the entire process can be planned and / or simulated in its entirety.

The simulation of the overall process can be uniformly integrated in the first program, so that for example by means of a button the production process according to the current previously planned configuration, for example based on data that a user has supplied the first program (material flows, processing capacities, cycle times, etc .) or based on real-time data from a real production, can be simulated. Likewise, the simulation can represent a separate module.

In any case, however, all the processes and processes that can be assigned in accordance with today's usual separation of logistics and manufacturing, can be mapped on a program interface, so that the entire process can be planned and / or simulated holistically, i. without resorting to further software programs. The holistic planning and / or simulation of the overall process can be reflected in the architecture of the first program in such a way that all parameters required for controlling and / or regulating the overall process (eg any actual values and desired values of a process) are assigned to the production factors can be assigned to planning objects. The first program thus has all the relevant parameters required to operate the factory and perform the overall process, and can take their influence into account during planning and / or simulation. The planning and simulation functions of the first program can also cover all planning functions, including the support of their "temporal" subdivision into product planning, process planning and series planning.

By means of the second program, the entire process actually taking place in a factory can now be controlled on the basis of the results of the first program. By means of the second program, all processes occurring in the overall process can be controlled with regard to the production factors. For this, the second program has interfaces through which it can communicate with any physical object involved in the overall process. Each physical object may receive data from the second program and / or transmit data to the second program. The physical objects can be sensors, robots, goods containers, conveyor belts, tools, components to be installed (which are provided, for example, with RFID elements (RFID, radio frequency identification), in German, for example, "Identification with the aid of electromagnetic waves") or also to act people who are assigned electronic devices and so they can be involved in the second program data technology.

From the point of view of the software architecture of the second program, it is irrelevant whether, for example, a part required for production is supplied to it from outside the factory (classic logistics process) or if a part is taken from a material container by a robot and to a product to be manufactured is attached (classic manufacturing process). Each of these is a time sequence of activities that are more precisely specialized, for example, on the basis of parameters such as a (standardized) job description, process duration, tolerance of the process duration, used materials, auxiliary and operating resources, error cases, etc.

Both in the first program and in the second program, the entire logistics can be mapped, that is, the entire supply chain from the place of origin of a part to its place of requirement in the factory. Orders and orders can be taken into account, whereby Advantageously, employees from the logistics use a different mask of the first and / or the second program than the employees in the production. In other words, the first and / or the second program may be used at the core both in departments dealing with logistics and in departments involved in manufacturing. Depending on the department, however, a different mask can be used in which the focus is placed on the characteristics of logistics (eg, orders, incoming orders, material flow) or on production characteristics (eg utilization of production areas, wear on equipment). Of course, a substantially identical mask can also be used in both areas. In addition, in the first program as well as in the second program, all production areas, which must pass through the future product itself and its sub-modules through to the finished end product, can be mapped.

The present method can also be based on virtual factories, ie spatially distributed production facilities and / or production networks for the production of the product or the sub-modules required for this purpose. The spatially distributed manufacturing facilities and / or manufacturing networks can be treated in the first and / or in the second program data technically and visually as a coherent unit. Thus, the term "factory" as used herein is not limited only to spatially related operations but may also refer to spatially distributed manufacturing facilities participating in the overall manufacturing process.

Furthermore, the method described here is applicable to all types of production, such as workshop production, island production, flow production or series production.

Likewise, the special case of flow production is covered by virtual production lines, in which the product is transported between individual production stations, whereby at least one work step takes place at each station. The material required for the production of the product is delivered to the production stations as needed. Virtual production lines can be highly flexible and individual paths for each product, which differ significantly from today's "rigid" production lines. Each product to be produced can be transported along an individual production path to different production stations, depending on the required modifications and degree of individualization.

The overall process is centrally controlled by the second program which, based on the data provided to it by the production factors, has at all times a real-time image of the overall process and therefore knows the history, its current state and its future for each physical object. Seen in this way, processes presented here can be understood as a further evolutionary step, which provides for the production of the future an "operating system" that is in terms of flexibility and efficiency.

By means of the method according to the invention, it is possible to integrate end users and business partners (for example, suppliers) into the value creation process, i. the entire process, starting with the possible receipt of orders via the planning and / or simulation of the entire process required for the production and until the final production and subsequent delivery of the final product. By merging the world of logistics with the manufacturing world in the context of the method according to the invention, this entire value added process can be efficiently planned, simulated and controlled.

According to further embodiments of the method, the first electronic data processing program may be identical to the second electronic data processing program. In other words, the functional scope of the first program and the second program may be united in a single program (hereinafter referred to as the program). By combining planning, simulation and control functions with regard to all production factors and the two areas of logistics and production in one tool, a complete process can be optimized globally across all degrees of freedom. Within the program there is no separation between planning objects, ie program-technical illustrations of physical objects in the planning and simulation tool. Control objects can be understood to mean program-technical representations of physical objects in the control tool. On the one hand, this means that in the ongoing operation in a factory, the "status quo" of the overall process can be grasped and always adapted by means of a tool. On the other hand, based on the current configuration of the overall process, the influence of planned changes on the overall process can be simulated. This ensures that the simulation takes place on the basis of current parameters of the overall process and thus no over-used process information is used. The program can be seen as a central control unit in communication with all the production factors used in the factory.

According to further embodiments of the method, the group of production factors further comprises data. The second program is so not only for the central control (coordination) of the classical factors of production human (ie man-made work), machine and material set up, but it also controls or coordinates the flow of data between itself and the factors of production and between the factors of production. Since the overall process in a smart factory is characterized by a high degree of autonomous communication between product and machine throughout the manufacturing process, in an exemplary manufacturing scenario in the smart factory, the second program may have data in relation to data predominantly overarching coordinating role be awarded.

According to further embodiments of the method, at least one instance may be associated with each physical object involved in the method according to the invention in the first electronic data processing program and / or in the second electronic data processing program. Mapping multiple instances may be required if a physical object is mapped using multiple instances.

In this context, the instance may be an engineering object in the first program, that is, a virtual representation of a production factor that is specified by its characteristics and used to represent / map the overall process in the first program. Likewise, the instance may be a control object in the second program, that is to say a virtual representation of a production factor which is specified by its characteristics and used to represent / depict the overall process in the second program. The engineering object can merge with the control object if the functional scope of the first program and the functional scope of the second program are combined in one program.

According to further embodiments of the method, each physical object involved in the method for producing a product may be assigned an address, which is preferably based on the Internet Protocol. In this way, every physical object, for example every physical object from the group of classical production factors, can be reached in terms of communication technology within the framework of the method described here. Engineering objects and control objects may be accessed via addresses as mentioned above e.g. IP addresses, with the corresponding physical objects communication technology coupled. The data exchange serves primarily to transmit process information (ACTUAL values) that are transmitted from the physical object to the at least one corresponding engineering object and to transfer process control data (DESIRED values) that the engineering object transmits to the corresponding physical object become. The required communication can be based on known communication channels (RFID, Bluetooth, WLAN, IrDA). Due to the availability of real-time data from the overall process, ie from logistics and production, the target values can also be calculated on the basis of the overall process. This enables control in real time to the optimum of the overall process - in contrast to today, where no holistic consideration and optimization of the entire value chain takes place but only sections of the overall process are controlled and optimized.

According to further embodiments of the method, the first electronic data processing program and / or the second electronic data processing program may have a suitable programming interface for each physical object involved in the method of manufacturing a product. As a result, the first program and / or the second program can be adapted to any factory environment and thus to various technical environments. A programming interface may, if required, be customized to each physical object so that communication between the first program and / or the second program may occur and conversion of SETPOINTS, ACTUAL values and other data between the electronic programs and the physical object works smoothly. The programming interfaces can figuratively act as translators, translating between the individual languages of the physical objects and the language worlds of the first and / or second programs. Thus, the first and / or second programs not only have full access to each physical object, ie, they can retrieve data from the physical object and also store data thereon. By centrally collecting and managing the data flows, each physical object can communicate with, ie communicate with, another physical object by means of the first and / or second programs, even if the one physical object has a different programming than the other physical object , The first program can access data from a physical To access an object and submit data to the physical object to define / map it as an engineering object in the software, and then to configure the physical objects of a factory according to a found or optimized global configuration. The second program can access data from a physical object and transfer data to the physical object to control it as a control object and configure it as part of an expansion of the factory or a changed configuration (eg, changed processes) according to the new specifications. In this case, advantageously, the data from a planned and possibly additionally checked by means of simulation configuration can be used directly and transmitted to the corresponding physical objects. In other words, configurations and scenarios can be planned and possibly additionally simulated in terms of the overall process. If the first program and the second program are programs, then a simulated (and found suitable) configuration can be loaded onto the physical objects, in particular the machines, by means of an appropriate command. Furthermore, the program can adjust the times for the updates or changes of the process modes of the corresponding physical objects so that a trouble-free migration from one process configuration to a second process configuration can take place. This can be done by re-configuring physical objects, such as a bow wave, to track a piece of material or a finished product at the factory, so that the next piece of material or next product to be manufactured is treated according to the new / updated operating mode.

According to further embodiments of the method, each physical object can be associated with at least one instance via its address, for example, as already mentioned above, the corresponding IP address. The instance can either be the corresponding engineering object or control object, ie the virtual representation of the physical object in the software environment. Thus, any physical object which is to be controlled in the context of the method presented here (for example an adhesive robot) or whose data is to be retrieved at least (for example a motion sensor) can be uniquely identified and controlled. The address assigned to each physical object can be used to create a link between the virtual planning, simulation and control world and the real world. At any time, a new setting, for example, from the planning, simulation, or control level, i. from the first and / or second program, for a physical object in the factory to be transferred to this.

According to further embodiments of the method, the overall direct control of the method by the second electronic data processing program may be based on process information transmitted from the physical objects to the instances in the electronic program in real time. The process information can be data of any kind, which is transmitted from the physical objects independently to the second program or actively requests the second program. By monitoring and controlling processes throughout the value chain, i. From logistics to the procurement of the required materials or raw materials through the manufacturing process to the finished product, based on real-time data, an industrial production process can be set optimally by means of the method according to the invention. Deviations from the set configuration can be detected instantaneously (i.e., in real time) in each area of the value chain. For example, it is then possible to react to the deviations ascertained by determining their influence on the overall process, for example by simulation, and then adapting the overall process in such a way that it optimally takes into account the deviation. Advantageously, when evaluating the influence on the overall process, all the other parameters of the overall process are updated in real time, so that the deviation can be identified very precisely and its influence on the overall process can be calculated / simulated very accurately. Through the holistic treatment of logistics and production within the scope of the method described here, the entire process can then be optimized in total, taking into account the deviation. In doing so, "blind spots" can be avoided, ie areas that are far removed from the area in which an adaptation is to take place, and in which the influence of the planned adaptation can not be estimated and can lead to inconsistencies.

Overall, the method according to the invention is characterized by a unified, comprehensive process, planning and / or simulation and operational control of processes in logistics and production based on a complete networking of production factors, ie man, machine and material. Preferably, these processes can be combined in an electronic data processing program in which the overall process is virtually replicated and can be controlled on the basis of real-time data from the overall process.

Further advantages, features and details of the invention will become apparent from the following description in which, with reference to the drawings, embodiments of the invention are described in detail. The features mentioned in the claims and in the description may each be essential to the invention individually or in any desired combination. Further For example, various embodiments of the invention may be combined to form another embodiment of the invention.

1 shows a task landscape that can be found today in industrial plants in production and planning.

2 shows a diagram in which a nowadays commonly used information technology implementation of a manufacturing management system is shown.

3 shows a diagram in which an information technology implementation of a manufacturing management system according to the invention is shown.

In 4 the embedding of an IT system is shown in a manufacturing landscape, which embodies the inventive method.

5 shows a diagram that illustrates how production is controlled and optimized today.

6 illustrates the operation of the production process platform according to the invention.

7 shows an embodiment of the production process platform that may be used to plan and possibly simulate and control an overall industrial manufacturing process.

8th shows a basic process flow in the planning tool according to the present invention.

In 9 a diagram is shown, which illustrates the mapping of real involved in the overall manufacturing process objects in a program level of the inventive method.

10 illustrates a practical example of the operation of the method according to the invention.

11 shows a pick-by-light shelf and its control according to the inventive method.

12 shows a diagram in which a schematic representation and operation structure of the planning tool according to various embodiments is shown.

13 shows a flow scenario in the control of a supply chain and the manufacturing process based on the pull principle according to the inventive method.

14 shows a flow scenario in the control of a supply chain and the manufacturing process based on the push principle according to the inventive method.

15 illustrates an example process flow in the production process platform.

In 1 is sketched a task landscape, which is to be found today in industrial plants in the production and planning. The framing field 100 should represent a manufacturing industrial enterprise. In the context of economic activity, such a company must plan tasks of the two core areas 110 and production 120 to solve. The strict separation of these two core areas leads to a first and most striking system or process break, which in 1 through a first jagged line 130 is indicated. Today's control of production 120 is based on specifications that were previously in the planning 110 have been defined. Not infrequently arise in the actual production control 120 Deviations from the planned state. Because there is no direct feedback from the production 120 in the planning 110 that forms in the planning 110 defined state not the actual production 120 from. To exaggerate, one can say that with the day of the production start in a factory the one in the planning 110 planned production state and the actual controlled state of production diverge. The control in production 120 does not take place directly from the planning 110 out, but from an implementation of in the planning 110 determined specifications.

To the classic tasks of planning 110 include product planning 112 , the process planning based on it 114 as well as logistics planning 118 , Goal of process planning 114 is the industrialization of the required process flows, whereupon in the planning of the automation technology 116 the required technical production facilities are determined. Parallel to these tasks, but separately from them, the logistics planning takes place 118 , Here is another process or system break, which by means of a second jagged line 132 is indicated. Nowadays the logistics planning takes place 118 usually completely separate from product planning 112 , Process planning 114 as well as the planning of the automation technology 116 that are considered more valuable for economic value creation. In particular, logistics planning takes place 118 with other electronic data processing programs. It is also mostly executed subordinate and must meet the requirements, which in the context of process planning 114 and the planning of the automation technology 118 have been defined, and can only be optimized in compliance with these "boundary conditions".

On the side of production 120 there is a further process or system break - by means of a third jagged line 134 indicated - between the production control 122 and the shop floor control 124 (German: Workshop hall control, production hall control). The production control 122 has the job of making plans from process planning 114 based on the planning of the automation technology 116 to implement in production. The shoopfloor control 124 On the other hand, the dynamic and flexible fine control of the production represents. As a rule, there is the jagged line through the third 134 indicated system break between the production control 122 and the shop floor control 124 because not all transport and production-specific specifications for the shop floor systems come from the production control. In practice, this circumstance can be linked to the fact that specific configurations are performed locally on PLC units (PLC: programmable logic controller) or PCs in the shop floor.

Another system or process break, by a fourth jagged line 136 represents, reflects the situation on the side of planning 110 again: Also on the side of production control 120 the logistics control takes place 126 separate from the production control 122 , In other words, there is no central control unit that controls manufacturing and logistics in an integrated way and, for example, can adjust logistics control in real-time when there are changes in production control. Additionally represents a fifth jagged line 138 another process or system break, which today between logistics control 126 and the logistics-related shop floor control 128 can be found. The one of the fifth jagged line 138 represented system breakage manifests itself in the same way as the just explained by the third jagged line indicated system breakage 134 ,

In the 2 The highly segmented planning and production landscape outlined in an industrial enterprise is also directly reflected in the way in which production is automated. In 2 is a simplified automation pyramid 200 shown which represents different levels according to the system accepted today. The underlying overall manufacturing process can take place in a factory or even a factory network. At the top level of the automation pyramid 200 is the company level 202 which at the same time is the level of planning 110 represents. As already explained above, planning tasks are performed in this level, a control of the production (eg control of robots) does not take place from this level. At the corporate level 202 Enterprise Resource Planning (ERP) is the process of deploying and managing resources such as capital, human resources, equipment, materials, information and communication technology to achieve the intended business goal. Two main tasks, which are the company level 202 are attributed to logistics planning 118 and the production planning 122 , Logistics planning 118 and the production planning 122 are carried out separately and not in an integrated process encompassing both subsections. Based on this fact is in 2 representative of a first IT system 220 represented, which for the logistics planning 118 is used. Another, second IT system 222 is used to production planning 122 perform. These two IT systems work independently of each other and there are no data objects that are kept in sync with each other in both IT systems.

Below the company level 202 is the plant control level or production level 204 which is mainly embodied by MES systems (MES: Manufacturing Execution System). The MES is characterized by the direct connection to the plant and automation technology in the factory, which enables its control in real time. Therefore, this is also the operating management level 204 designated level, as in 2 indicated, the area of actual production 120 assigned. For example, tasks such as production data acquisition, material management and quality management are performed here. These and other functions are in 2 collectively referred to as auxiliary functions, each of which usually requires its own IT system. Representing is in 2 However, only one IT system is shown, namely the third IT system 224 , with which various auxiliary tasks are done.

Another level, which together with the manufacturing level 204 the actual production 120 embodied is the shop floor level 206 , This level, in which the entire plant and automation technology is summarized, is obviously also to be assigned to the actual production. From an entrepreneurial point of view takes place in the shop floor level 206 through need-based control from the higher level, the actual added value. Those in the structures, which by means of logistics planning 118 at the company level 202 were created ongoing operational logistics covers the subareas of external logistics 212 (mainly procurement and distribution logistics), internal logistics 210 (Movement of goods at the factory site) and the final provision 208 the materials to the place of need. In the in 2 The scenario presented is operational logistics using a fourth IT system 226 settled. The entire production 120 which the manufacturing level 204 and the shop floor level 206 is cross-level by another, fifth IT system 228 controlled.

Based on the schematic representation of the current segmentation of manufacturing processes in industry in 2 you can see that a variety of IT systems are needed to plan and control the overall manufacturing process. As already mentioned, this subdivision is the immediate consequence of in 1 outlined way of thinking. It should be noted that the in 2 rather, can be seen in a representative manner for the respective areas and, in the industrial environment, depending on the complexity and scope of the factory, train the IT landscape via twenty individual systems. An overarching communication and a synchronization of cross-program data objects between the different IT systems do not take place. Therefore, it is also very difficult or impossible, a total optimum for the of the automation pyramid 200 to find the represented complete manufacturing process. It can certainly be found the optimum within an IT system, such as an optimum in terms of operational logistics. However, it can not be guaranteed that the resulting benefit synergistically through the other levels of the automation pyramid 200 propagated and ultimately optimally reflected in the overall manufacturing process.

Starting from the in 1 and 2 In comparison to this, the present-day situation in industrial production is the approach according to the invention in FIG 3 illustrates in which the automation pyramid 200 out 2 is shown. The different IT systems 2 underlying core tasks are shown without the associated IT systems. The reference numerals of the core tasks agree in the last two numbers with the reference numerals of the associated IT systems 2 match. Within the scope of the method according to the invention, only one IT system is used 330 For use, which allows the planning and, where appropriate, the simulation of the overall manufacturing process. Additionally optionally, by means of the IT system 330 the overall manufacturing process can be controlled directly. In general, it can be in the IT system 330 to act a data processing unit (ie, a computer program executable on a computer) from the first program and the second program. Alternatively, in the IT system 330 Functions of the first program and the second program to be united, so that the IT system 330 as a central and integrated IT system 300 is set up.

Out 3 It is clear that the inventive method over the previous approach, which in the 1 and 2 has significant advantages, which have already been discussed above. The in 2 presented automation pyramid 200 is based on an information technology isolated solution. By contrast, the flow of information and goods of the overall manufacturing process can be planned and / or simulated by means of the first program and controlled by the second program (it is again emphasized that in the context of this description the term "control" is used to regulate the term "control") "Includes). The first and second programs, unless their functions are grouped together in a single program, can be structured such that engineering objects in the first program and the control objects in the second program are compatible with each other in terms of their data structure and are continuously synchronized with each other. This ensures that the influence of every action of the user (eg parameter changeover) is considered globally from the point of view of the overall manufacturing process. In this way, the overall manufacturing process can be optimized to a global optimum. As in 3 Shown are the functions that exist in the IT system 330 are united across all three levels of the automation pyramid 200 , wherein the IT system embodying the inventive method 330 even the ERP level can be assigned.

In 4 is a diagram 400 which illustrates the embedding of the IT system in a manufacturing landscape, which is set up to carry out the method according to the invention. The objects 410 - 420 represent spatially separate factories, which together form a factory network. As already mentioned, in the context of this description the term factory can always also mean a factory network. From the perspective of the method according to the invention, the planning, simulation and control of the overall manufacturing process is insensitive to a spatial distribution of factories that together form a factory network as a functional unit. The IT system 430 which comprises the first and the second program or is embodied by a program which offers the functional scope of the first and second programs, functionally represents a control center which monitors and controls the overall manufacturing process across the plants. The investment and Automation technology in each of the factories 410 - 420 is via appropriate interfaces with the IT system 430 connected. However, it is also envisaged that the individual factories 410 - 420 can exchange data with each other. These data transfers are through the lines between each factories 410 - 420 indicated. The data to be exchanged may, for example, be uncritical parameters which are relevant only in a subset of the factories. To the IT system 430 To relieve this data can be exchanged directly between the factories.

This in 4 shown diagram 400 but can also be used to describe another fact. If you restrict yourself to a factory, this is illustrated in 4 illustrated diagram 400 the interplay between the IT system 430 and production factors, which then pass through the objects 410 - 420 are represented. Between all factors of production 410 - 420 and the IT system 420 a data transfer can take place. However, it is also a direct communication between the individual production factors 410 - 420 conceivable, for instance between a material part provided with an RFID transponder and a robot gripping arm. This type of communication is through the connections between each element 410 - 420 represents.

To further clarify the difference of the present invention to the present approach in the planning and control of industrial production processes, a look at the present day way of controlling production may help. In the diagram 500 in 5 illustrates how production is controlled and optimized today. At the lowest level are three exemplary production factors 504 ie a robot 501 , a photocell 502 and a shelf 503 to accommodate various parts required for production. Each of the factors of production 504 In particular, every automation technology (robot, shelving system, sensor) is usually supplied by another manufacturer. As a result, each manufacturer supplies its own automation technology with its own application 508 by means of which it can be controlled. Between an application 508 and the associated production factor 504 is usually a database 506 interposed. During production, each system can be separately monitored and controlled, and the associated work process can be optimized. In the standard process described so far, however, there is no overall control and no data-spanning data exchange.

In 5 are further elements 510 which represent, as it were, a first evolutionary stage of the standard process described so far. It will be the data from the individual databases 506 the respective factors of production in a central or superordinate database 514 collected what's in 5 through the dashed arrows 512 is indicated, for example, in a cloud. Since large and complex amounts of data are generated here, the term big data (German: mass data) is usually used. Based on this centrally collected data, appropriate data analysis technologies can be used 516 , ie processing and evaluation of these large amounts of data. In the context of data analysis 516 In this first evolutionary stage, production data can be collected centrally, relationships analyzed and individual processes optimized individually and in isolation. However, the evaluation of the data from the central database is limited to the establishment and verification of case scenarios.

Another evolutionary stage, which is based on the in 5 shown diagram 500 can be explained, is that the central data analysis 516 is not limited to the verification of case scenarios, but that based on the in the parent database 514 stored data the data analysis 516 processually analyzed. That is, process-mining technologies can be used by means of which based on the data from the parent database 514 individual processes from production are reconstructed and analyzed. For example, individual steps from different systems can be combined into one process (eg all the steps required to insert seats in a car) so that the process as a whole can be visualized and analyzed. However, as in 5 indicated, the arrows representing the data flow run 512 only in one direction, ie from the individual device databases 506 to the parent database 514 , This aspect reflects the fact that nowadays the flow of data from the source to the programs, by means of which in the course of the parent data analysis 516 Processes are visualized and analyzed, unidirectional. In other words, the process mining programs are a pure analytic instance where insights are gained that can be incorporated into the controller. However, there is no provision for direct influence from the level of such programs on production.

The inventive method is based on a completely different approach, which in 6 is illustrated. The invention is based on a production process platform (a platform embodying the first and second programs) in which the The overall manufacturing process can be planned, integrated, and optimized in real-time using a variety of techniques such as deep learning (modern type of machine learning). A significant difference to the in 5 presented approaches, which are widely used today in the industry, is that used production factors 404 , in particular the machines used, possibly tools as well as the workstations where people perform work, over a network with a central hub, such as the IT system 330 (please refer 3 ) are networked. This central hub thus has access to (essentially) all machines, tools and workers involved in the manufacturing process. This can be done as in the diagram 600 in 6 shown, each production factor a unique address, such as an IP address 602 be assigned. About the address 604 takes place between each networked object and the production process platform 620 a bidirectional data transfer 604 instead of. That is, the production process platform 620 has access to the data of each of the objects 401 . 402 and 403 but it can also contain data, eg instructions, to the objects 401 . 402 and 403 to transfer. This can be done within the integrated production process platform 620 planned production state from the same platform 620 can be used directly for real-time production control. Furthermore, there is no separation between logistics and production in the context of planning according to the invention, if necessary. Simulation and control. The (partial) processes contributing to the overall manufacturing process can be used in the production process platform 620 From a classical point of view, they are mapped as integrated processes that contain both logistics steps and production steps. For example, a process strand related to the incorporation of consumer electronics into a car may begin delivery of the consumer electronics, their transportation and storage, and their route to the factory site as well as the final installation steps. If the process plan changes during ongoing production, for example, by dividing the work steps from one workstation to two workstations, this automatically becomes visible in the process strand and the delivery of the parts that were once delivered to a workstation in the factory automatically takes effect delivered to one of the two newly designated workstations. Because planning and control integrated into a production process platform 620 If there is a rescheduling of the operating status of a factory, the controller is automatically updated (possibly only after a consistency check of the planned change, for example by means of simulation). Conversely, replanning always takes place on the basis of the current operating status of the factory, since the planning takes into account the data reported in real time from production. The inventive production process platform described here 620 can be seen as an implementation of the concept of Internet of Things (German: Internet of Things) in production and logistics.

In 7 is the structure of an embodiment of an IT system according to the invention 700 (hereinafter also referred to as production process platform), which is based on the method according to the invention. It can be used for planning and, if necessary, simulation and control of an overall industrial manufacturing process. The IT system 700 can be the first program 702 as a kind of planning and, if necessary, simulation editor have for the planning and, if necessary, for the simulation of a configuration of the production factors. The IT system 700 may also be the second program 704 have, which is set up as a control module for controlling the production factors in the planned production operation. The first program 702 and the second program 704 can coexist as independent modules. In this case, however, the engineering objects would be in the first program 702 and the control objects in the second program 704 be compatible with each other and synchronized with each other. Both programs can then have the same interfaces for information technology communication with the production factors. In a preferred embodiment, the first program 702 and the second program 704 Submodules of a uniform IT system 400 so that it is an engineering object from the sphere of the first program 702 and a control object from the sphere of the second program 704 a uniform data object within the IT system 700 is. Regardless of the exact data architecture of the IT system 700 this can also be a database 706 in which data relevant to the overall manufacturing process is stored. The data may be, for example, information about materials (eg raw materials or vendor parts) or orders received. Information about the materials can, for example, be determined from bills of material, and the orders received can be retrieved from the ERP. Furthermore, in the database 706 from the IT system 700 generated data, such as the layout plan of the factory or the process plan. Based on such data, then the control of the overall manufacturing process can be done. By integrating the planning function (possibly including simulation) and the production function in an overall solution, the process of the invention closes the process-technological and IT-technical gap between planning and operative control as well as between production and logistics.

In the 3 Task areas logistics planning 320 , Production planning 322 , Auxiliary functions 324 from the MES level, manufacturing control 328 and control of operational logistics 326 which today are all handled by means of independent IT systems (as in 2 1), according to another embodiment, all can be handled by means of standardized process modules, for example "apps", which in their entirety represent the IT system 700 form. In one preferred embodiment, the process modules may all be embedded in an integrated overall solution or, according to the two task fields of planning and possibly simulation on the one hand and the controller on the other, be present separately in two programs, the first program and the second program.

In 8th is a flowchart 800 which illustrates a basic process flow in the planning tool according to the present invention. The process flow starts with the technical development 802 of a product, for example on the basis of a specification. To the technical development 802 closes the product planning 804 at. In product planning 804 the process of equipment, operations and / or operations is planned to produce the designed product. Here, the planning of the added value and the process flow is part-related. In this context, part-based means that product planning is based on parts types such as "steering wheel", sometimes directly with part numbers of the corresponding parts. The product planning 804 takes place independently of the factory, ie without including the factory layout. At this point it becomes clear that it is irrelevant to the method according to the invention whether ultimately the product is manufactured in a factory or in a factory network. In the course of product planning 804 Every planner involved in this phase works on an allocated parts pool. The validity of planned work steps can be verified by the BOM. After completing product planning 804 there is a product plan.

To the product planning 804 shoots the process planning 806 at. In process planning 806 The part-related process flows determined in the previous phase from the product plan are assigned to stations and work centers within the factory. More specifically, the physical layout of the factory is planned (colloquially plant model), for example comprising one or more plant, segments, trades, lines, belt sections and stations. Per station, workplaces can be planned according to capacity requirements. In addition, the required resources are defined and assigned to work and / or test steps. Finally, the process flow at the defined workplaces is determined. After completion of the process planning 806 there is a process plan.

After successful and completed process planning 806 follows the series planning as the last step 808 , As part of the series planning 808 Product planning activities take place 804 and process planning 806 , Here, however, the focus is on Umtaktungen, ie on a reassignment of operations / steps to stations and workplaces. Workplaces can be moved to other stations along with all assigned work and / or test steps and resources. Likewise, assignments of individual work and / or test steps can be transferred to other stations or workplaces. Furthermore, as part of the series planning 808 Change the order in the process flow in a work center. Determined resources and work and / or test steps assigned resources can be changed, for example, added or deleted.

The inventive method is applicable to all types of production previously defined in the relevant literature, for example, on the workshop production, the island production, the flow production or about the series production. Workshop production can be understood to mean production by skilled personnel on similar machine installations which are spatially and stationarily arranged in a factory, the delivery process being of discontinuous nature. The term "in-can production" can be understood to mean the production of products in sub-families, where each part of a part-family has a similar production process and each sub-family is processed by a number of work-units. The resources and workers in a work unit are grouped spatially to form the manufacturing islands. By series production can be understood a production in which the resources involved and the workplaces after the production process, ie according to the order of the individual steps are ordered. In the series production, the production takes place in batches, with the workpiece to be produced then being transported in batches from one work site to the next; there is no rigid connection between jobs. Under flow production can according to the VDI directive 2815 a gradual production of material and products in spatially contiguous and arranged according to the manufacturing process local workplaces of a sub-area for a given type of division to be understood with complete succession, rigid timing and using different workers who do not change during the order execution. In particular, through the integrated treatment of logistics and Production processes are all of these different types of manufacturing the method according to various embodiments accessible.

Likewise, by means of the method according to the invention, types of production of different degrees of mechanization (manual, mechanized or automated) can be treated as well as types of production which are from the sales market to a warehouse / market production or to a customer order production. Finally, the method according to the invention is based on production types of different repetition types, i. Mass production, variant production, series production or individual production, applicable.

The following is based on the in 9 shown diagram 900 explains the basic planning and control of a total manufacturing process according to the inventive method. The dotted dividing line in the diagram 900 divide this in half. In the upper half is the program level 920 , such as the program level of the production process platform, which is set up for planning and / or controlling the overall manufacturing process according to the inventive method. In the lower half, on the other hand, is the physical plane 940 represents, ie the factory or the factory network together with all production factors located therein.

At the program level 920 are planning and control objects 922 - 930 shown. Based on an order 922 can use the planning tool to produce the material required to manufacture the ordered product 924 be planned. The required material 924 can be individual steps 926 be assigned. This process is in classic product planning 650 includes. The work steps 926 can then, as in the previous one 8th explained in the course of process planning 652 workstations 930 and resources 928 being assigned, whereby also resources 928 directly workstations 930 can be assigned. All these processes can be planned and possibly simulated by means of the first program. An appropriately configured overall manufacturing process in a factory can then be controlled by the second program.

Between the planning and control objects 922 - 930 The program level and the corresponding physical objects are connected by data. So all objects can be on the physical plane 940 communicatively communicable with corresponding program objects of the IT system. In other words, any planning and / or control object 922 - 930 be linked to a corresponding physical object by means of a data connection. These communicative connections are in the diagram 900 in 9 indicated by dashed arrows. In the assignment between the program level 920 and the physical level 940 In mathematical terms, it can be a surjective mapping, as it may be that the same physical object is assigned to several program objects. For this purpose, a physical object can for example be assigned an IP address via which it is uniquely identified. Furthermore, RFID transponders and RFID readers can be used, for example, to identify workpieces or product parts and to track them within the overall production process. In 9 So that's the order 922 modeling program object with products 942 linked in the factory, for example with half-finished products or with workpieces still to be installed. These can be provided, for example, with RFID transponders and thus be identifiable in the overall production process. Furthermore, the program objects representing materials required for fabrication may be linked to the corresponding RFID tagged materials at the factory. Also workstations 948 and resources 950 are with the corresponding program objects from the program level 920 linked, for example via IP addresses. Workers can work through the workstations 948 be communicatively reachable or be identifiable. In further embodiments, however, each worker may have an electronic terminal through which he receives information from the program level 920 and also upload information into it. The terminal may, for example, be a touch-sensitive display or AR glasses (AR: augmented reality) and also have a microphone and a loudspeaker so that the communication with the worker can also be voice-guided. In such an embodiment, each worker may then have at least one program object in the program level 920 be assigned.

Overall, the illustrated in 9 shown diagram 900 in that by means of a link between program objects 922 - 930 (ie, planning or control objects) and physical objects 942 - 950 Within the scope of the method according to the invention, a holistic control of the physical objects and thus of the overall manufacturing process is made possible.

A practical example of the operation of the method according to the invention is shown in FIG 10 illustrated. Based on the figure, a control of an assembly workstation will be explained, which has a pick-by-light (German: picking by light) shelf. The control comes from the production process platform 620 out, which is symbolized by a cloud. The process to be explained was used in the production process platform 620 planned and appropriate instructions were transmitted to the affected production factors. In the present case, a pick-by-light was configured accordingly.

The control process begins with a first step 1002 in which a picking instruction is displayed to a worker at the corresponding workstation, for example on an electronic display. In a further step 1004 The pick-by-light shelf is controlled and the designated tray, from which the worker is to take out a part, is marked, for example by means of a light indicator. In the following step 1006 is waited for the input of the worker, which confirms, for example, by confirming the appropriate button, the removal of the part. Instead of the manual key operation, for example, a scanned on the pick-by-light shelf scanning device can be used, at which the worker scans the removed part (optically, via bar code, or electronically, via RFID transponder). After successful detection of the removal of the correct part, the worker can then in a further step 1008 the pick result will be displayed on the electronic display.

Based on the scenario just described, the flexibility and performance of the method according to the invention should be clarified. Suppose the worker at the assembly workstation wishes to reorganize the pick-by-light rack to improve his working economy, such as having to bend less often to lift heavy parts. By means of the production process platform 620 He can even move the storage space of the heavy grade to the top of the shelf and swap it for the storage space of a lighter grade. After rescheduling, this change can be made, for example by clicking a button in the production process platform 620 to be taken to the controller. Because within the production process platform 620 If there is no separation between logistics and production, the logistics planning is immediately adapted and adapted to the fact that now the heavy grade is placed in the upper shelf and the light grade is placed in the lower shelf.

The integrated planning and control of logistics and production open up further, previously unknown possibilities. For example, a shelf that has a limited number of storage compartments can be virtually populated with a number of part types that is larger than the number of compartments. That is not possible today. For example, certain parts that are rarely installed on an assembly workstation may be merged into a compartment according to the order in which they are used. This is possible in the context of the method presented here, since the picking instructions are known or can be calculated over the next assembly cycles. Based on this knowledge, the intermediate storage can be controlled so that the rarely used parts are placed in the predicted order, for example, in a box and then occupy only one compartment on the shelf.

The two exemplary scenarios show that the combination of planning and control functions, which also include logistics and production, differentiates the inventive method from the classic planning and control concepts used separately today.

In order to enable planning and control of the complete overall manufacturing process, as part of the method according to the invention, the material storage at the respective workstations is digitally integrated into the main system. In 11 is an exemplary pick-by-light shelf 1100 outlines which nine subjects 1102 (only the upper left compartment is exemplarily provided with reference numerals). Each of the subjects 1102 may include a storage box containing parts used in assembly at the associated workstation. As further in 11 represented, is every subject 1102 of the shelf 1100 an own address 1104 assigned, for example, an IP address. Every subject 1102 The shelf also has a pick interface 1106 which are under the address 1104 a subject 1102 can be addressed by the production process platform. Under the pick interface 1106 For example, a device can be understood which can provide a worker (eg acoustic or optical) signals or information and can also accept inputs made by the worker. This can be done by the pick interface 1106 an output means (eg, an LED display or a speaker) and an input means (eg, at least one key or touch-sensitive surface). In step 1004 in 10 For example, an LED indicator on the pick interface 1106 of the shelf 1102 be switched on and signal to the worker that he should take out of the displayed shelf part for mounting. In step 1006 in 10 then the worker can confirm the successful removal of the part by pressing a button.

By such electronic integration of the shelf 1100 as an interface between classic logistics and classical production in the production process platform according to the invention, the removal in real time to be monitored and controlled. This means that the stock of the shelf too at any time and based on anticipation of future products, parts that will be consumed in the foreseeable future can be refilled in a targeted manner. In the 11 The view shown above shows the front of the Pick-by-Light shelf 1100 , The subjects 1102 on the back of the shelf 1100 However, they can also be equipped with electronic means, which at the replenishment of the inventory of the shelf 1100 indicate which subjects should be filled. At this point, it becomes clear that logistics and production merge seamlessly in the production process platform. A change in logistics is automatically taken into account in production and vice versa. As already mentioned, for example, in very seldom used parts (but also generally) on a shelf, the logistical part of a worker's work could be the removal of the correct part from the pick-by-light shelf 1100 and transporting this part directly to the assembly site to be relocated to logistics. At least one compartment of a pick-by-light rack could be equipped with different parts of the same type (eg with differently colored trim strips) in the order in which they are used. For this purpose, however, the logistics must have precise knowledge of the production plan or the loading of the shelf with assembly parts, a classic logistical task, must be controlled according to the production plan. Such a procedure is now possible with the method described here since logistics and production can be planned and controlled uniformly.

For the sake of completeness it should be mentioned that classic shelving systems without the in 11 shown pick interfaces 1106 can be retrofitted with such facilities. These can be the pick interfaces 1106 , which may be formed, for example, as palm-sized devices, to the frame of a shelf, for example, via the shelves, are plugged and connected to a control device, which can also be attached to the shelf. Such a retrofit requires little time, so that it can be done, for example, during a break in which a production line in a factory stands still. In the meantime, until commissioning on a pick-by-light 1100 Modified shelves, the production can continue and the shelf can continue to be used for the time being as a standard shelf.

When using the method presented here, the sorting task of logistics, so the loading of a shelf with the right, so be deposited in a particular shelf parts are also done by the production process platform. That is, the parts can be placed in any empty shelf 1102 be filed. For example, the shelf can use barcodes or RFID tags 1100 independently identify which parts are where and submit relevant information to the production process platform. As a result, the production process platform can direct the workers through the picking interface so that the right parts are always removed from the shelf during assembly 1100 be removed.

In 12 is a schematic representation and operation structure of the planning tool according to a possible embodiment shown. It should be noted that the illustrated structure corresponds to only one of many possible rendering and presentation modes of information about the overall manufacturing process. Of course, the scope of in 12 For the purpose of simplified representation, the information shown is substantially reduced and is intended primarily to qualitatively convey the functional principle of the planning tool.

The layout plan of the factory can according to one embodiment by means of classical tree structure 1220 being represented. It shows the state where a specific workstation is selected in a factory. In detail, it can be seen from the example shown that the work considered 1222 N has production lines, of which in the diagram 1200 in 12 only the first production line 1224 and the Nth production line 1232 are represented. From the first production line 1224 is a certain xth band section 1226 selected and in this x-th band section 1226 is clock Y (reference number 1228 ). After all, this is the zth workplace 1230 selected. In the example shown, the planning tool is used in a flow production. For other types of production, for example, instead of the x-th band section would be 1226 An xth manufacturing island selectable. The tree structure shown 1220 can be adapted to every type of production. The factory layout can be done by means of the exemplary tree structure shown 1220 be presented in a structured way regardless of the underlying production type and thus analyze every workstation. However, the exemplary tree structure shown for representing the factory layout can be structured according to other guidance parameters or it can also contain other parameters. In addition, the mandatory in 12 shown order for the subgroups. In other words, this means that the sequence of the respective subgroups can be adapted arbitrarily - depending on what is advantageous for the operation in a certain moment. For example, the production lines 1214 or manufacturing islands of a factory first after clock cycles 1228 instead of band sections 1226 be ordered.

After selecting a job 1230 can take place in this workplace Work processes are displayed. This can be done, for example, by means of the object field shown as an example 1240 respectively. These are the ones at the selected workplace 1230 parts used as a place of requirement 1242 listed. In general, program objects can be created and parameterized for all IP-capable, physical production factors involved in the overall production process. As shown, each of the parts 1242 for example, a resource 1244 and one operation 1246 be assigned. In addition to the operation 1246 the associated standard process 1248 be specified. It goes without saying that the order in which the parameters 1242 - 1248 can be adjusted as needed. The in 12 shown embodiment can be seen that at the considered x-th workplace 1230 the third part (third element from the top in the column of parts 1242 ) is used in a standard process of shoring, which can be checked by means of a scanner as a resource, whether the right third part is attached to the product to be manufactured.

The key point is that the example object field 1240 Contains desired values and actual values, the latter being retrievable in real time from the first program and / or the second program. The second part in the parts column 242 associated resources Pick-by-light shelf (second element from the top in the second column resources 1244 ) may be communicatively coupled as a program object via an IP address with the corresponding genuine factory-mounted pick-by-light shelf. All parameters that define the planning object and / or the control object Pick-by-light shelf can be transferred to the physical object Pick-by-light shelf in real time. The scheduling tool may collide all inputs made and, for example, warn of inputs that are inconsistent with the current configuration of the overall manufacturing process. For example, adding more work to a workstation may result in one asset being in use for a longer period of time, and thus being unavailable for another, so the other operation must wait for the asset to be released. This in turn can lead to delays in the other workstation and overall delays in the corresponding band section. This in turn can influence the internal logistics chain. Since the control tool, which is set up to control the method according to the invention, has both the process plan for assembly and logistics processes, a corresponding warning can be output. This is only possible because in the planning tool the production planning and the logistics planning are combined on a single platform. Therefore, both logistics processes and assembly processes can be grouped under one work center. The parameters that define the logistics processes and assembly processes can influence each other and this influence can be detected and become in the context of the method according to the invention. If necessary, a planned scenario can also be simulated in the planning tool at any time to ensure that i) no inconsistencies in the overall production plan are included and ii) optimization options are identified and exploited to move the overall manufacturing process to a global optimum. Due to the communicative coupling between the production factors and their corresponding program objects in the IT system, a planned configuration, which may have been optimized by means of simulation, can be transferred directly to the factory automation and automation technology in the factory, in colloquial terms supercharged.

The associated control tool according to the invention may have a similar structure as the planning tool. Through the coupling between the control objects and the means of production in the factory, the control always takes place on the basis of actual values, for example provided in real time, from the overall production process. For example, the control tool can autonomously determine the actual values of the production times and process times from the data queried by it and, by comparison with the target values, ascertain slowly occurring change processes, for example fatigue of the employees or signs of wear on the technical systems. Processes in production and / or logistics can be selected on a case-by-case basis, that is, depending on the upstream processes from which they are directly dependent. For example, as manufacturing times and process times increase at a particular workstation, the control program may determine that a delivery drone does not need to deliver the material required at the workstation for the time being. For example, during this idle period, the drone can be serviced. The peculiarity of the method described here is the close integration between the planning tool and the control tool, in a particularly preferred embodiment even its integration in a program, which allows a smooth transition between control and planning of both logistics processes and control processes. That is, based on any current operating situation, a planning scenario can be generated, for example, when the overall manufacturing process is to be extended by operations or technical facilities, or when it is to be checked that production is performed close enough to the global optimum. additionally "what if" scenarios can be simulated and optimal target values can be extracted from these, which can then be directly transferred to the respective production factors. The above objects have such a high complexity, in particular in the manufacture of complex modern consumer goods such as vehicles or consumer electronics articles, that they require the use of electronic data processing equipment (computers).

From the foregoing detailed description with reference to the figures, the difference between classical MES systems and the IT system is clear, which is set up for carrying out the method according to the invention. Whereas classical MES systems today offer networking of the entire production, including shop floor, for the purpose of control, but excluding logistics, the inventive method presented here is based on networking of the entire production, including shopfloor and also logistics. In addition, in the context of the method according to the invention, a comprehensive planning of production and logistics, which in classical systems, such as based 2 is not the case, since there the planning tasks in the two areas are solved separately.

In the context of the description, the term station or workstation can be understood to mean the combination of machine, personnel and tool (equipment) into a functional unit. The term workplace can be understood to mean a working area of a worker within a station, with one station having several work stations. The term clock can be understood as a time interval in which the product to be manufactured is moved from station to station. The term timing can be understood as the assignment of operations or work steps to stations. The term operation can be understood as the summary of work steps, whereby this term is also often used as a synonym for the term work step. A work step can be understood as a time-consuming activity that a person or a machine performs. The term manufacturing time can be understood as the time required for a person to carry out a value-adding work step on the product to be manufactured. By contrast, the term process time can be understood to mean time that a person needs to carry out a non-value-adding work step (for example, go, wait). However, this may also mean the time required for a machine to perform a work step.

In 13 the control of the supply chain and the manufacturing process of a component, for example a switch module steering column, is illustrated according to the method according to the invention. The process chain shown, the steps 1302 - 1320 has runs in the production process platform according to the invention 1330 from. The illustrated control process is based on the pull principle, ie on a demand-driven control of the processes. This means that used material triggers the logistical replenishment process (eg via Kanban). The control is done here, so to speak, based on the material consumption of the past. In 11 are in addition to the process strand within the production process platform 1330 notes on the left side events that belong to the respective steps. The arrows indicate whether the flow of information from the events to the production process platform 1330 or vice versa.

The illustration begins with the loading of a component onto a transport truck at the step 1302 , The information about this state passes, for example, by scanning and / or a GPS location of the transport truck. The production process platform 1330 may also have access to data from the contracted logistics entrepreneur and / or empirical data on the duration of transport trucks. From this, delivery times for the goods in a factory can be determined, if necessary also corrected on the basis of current traffic information. The delivered goods are registered on receipt at the factory at the goods receipt and can be stored. These operations can be done in the second step 1304 in the production process platform 1330 can be mapped, where information about quantity, time of arrival and place of storage can be recorded, for example by scanning. In a further step 1306 The transport of parts from the warehouse to a workstation in the factory can be done. This process can be an automatic reordering 1318 triggering at the supplier if the stock falls below a target value, for example due to removal from the warehouse. On the other hand, the transport of a part from the Langer to a workstation can be triggered by the removal of the part from a shelf at a workstation in the factory, such as when the number of these parts in the shelf falls below a target value. With anticipation of the further steps can therefore be a requirement 1320 of the part from the internal warehouse by consuming the part at the associated workstation. After initiating the transport of the part in step 1306 from an internal warehouse to the workstation, the part becomes after completed transport in the following step 1308 stored on the shelf at the workstation. The information about a loading of the shelf with new parts can be generated by scanning and sent to the production process platform 1330 be transmitted. For this purpose, a container in which the newly supplied parts are included, have a bar code or an RFID transponder. Alternatively, on the back of a shelf, which is filled by the warehouse staff, electronic displays including confirmation buttons may be appropriate, such as in 11 have been described. Regardless of the way the assembly of the shelf is determined, the deciding factor is that the production process platform 1330 always about real-time data regarding the 13 and the entire process chain is controlled on this basis and not based on values from "further" past.

The next steps are similar to those 10 , That is, in step 1310 is indicated to the worker by means of a display in the workplace that he should remove the part from the shelf. In the following step 1312 is from the production process platform 1330 activates the pick interface on the appropriate shelf of the pick-by-light rack. This is done in the usual course of things in step 1314 the removal of the part from the shelf, the removal is confirmed by the worker, for example, by pressing a button on the pick interface. As mentioned above, the removal of the part can automatically be an internal reorder 1320 trigger when the number of parts remaining on the shelf falls below a specified setpoint. The removal of the part from the shelf and the confirmation of removal by the worker can be done by the production process platform 1330 with the installation time 1322 of the part. In the last step 1316 the worker can be shown the pick result by a display on the workstation for confirmation.

At the in 13 shown diagram shows that the internal reorder 1320 the consumed part is triggered by its removal or installation time. By means of the production process platform 1330 can, as shown, the steps 1302 - 1316 planned in the context of the process, possibly simulated and also controlled, whereby there is no separation between logistics and production. In the example scenario shown, it can be seen that an event in production - the installation of a part - can automatically trigger a logistics process. Through the complete networking of the production factors (eg resources involved in the represented process) is in the production process platform 1330 always the current operating status of the factory shown.

By means of the method according to the invention can also be calculated at any time, taking into account the current operating state, which part is required at what time at which workstation. On the basis of such a preview, the delivery parts can then take place. This principle is in 14 shown. Here serves as the basis of the same process as in 13 , which will not be described again. Unlike the in 13 However, the scenario shown here is the repeat order 1320 or subsequent delivery not directly by the installation time 1322 certainly. Rather, the reorder will be through the production process platform 1330 based on a time forecast 1402 of installation time 1322 certainly. In extreme cases, all parts required for production can be controlled as JIT / JIS parts and thus delivered as "preview parts" to the workstations.

Nowadays, there is no consistent inventory count including the local warehouse at the demand location (line inventory). Thus, no optimization of the stocks in real time in the entire logistics chain - with regard to the stocks required in the future - is possible. The transports to the line take place in each case from the trailer station or supermarket in which the parts are present. There are no "mixed" transports in which several trailer stations and supermarkets are approached one after the other and from this a need-based replenishment mix of material is put together. The required parts are delivered to firmly defined shelves on the line. If the number of variants of a part (for example, colors of a fitting trim strip) exceeds the number of shelves on the line, then the picking of the part takes place in an area upstream of the line.

When using the method according to the invention, there are significant advantages over the current situation. On the one hand, the material supply can be consumption-controlled in the preview. The control of the replenishment of parts then takes place on the basis of exact future consumption. This allows only the exact material to be delivered to the line which is there in a time slice for the next x objects to be manufactured, e.g. Vehicles, needed. In extreme cases, where x = 1, it is a JIS cart delivery for the workstation in question. In addition, the transport can be controlled so that mixed traffic is possible

After so far in numerous examples, the control of processes has been described according to the inventive method, will be discussed in more detail below on the planning and control process. In 15 is a possible process flow within the production process platform illustrated. The process flow shown corresponds to only one of many possible embodiments of how a user can interact with the production process platform. The program interface of the production process platform can be set up so that the in 15 described measures.

The in 15 illustrated process flow 15 starts by selecting a part from a group of rushes 1510 used in the value chain. They are an example of a first part 1502 and an aw-part 1504 shown, wherein the number of selectable parts w can become large depending on the complexity of the final product. The planning process can thus begin with a first selection A, in which the corresponding part is from the group 1510 is selected. In this example, the scenario is based on the first part 1502 illustrated. The group 1510 may contain the total number of parts used or may also constitute a subgroup, for example all parts required for the construction of a dashboard.

After selecting the part, these activities can be selected from a group of activities 1520 be assigned. In the present example are a first activity 1522 and an umpteenth activity 1524 shown. The group of activities 1522 can contain predefined activities. In addition, the group of activities 1520 be limited to activities that are usually performed in relation to the selected part. If it is the selected first part 1522 is a rearview mirror, the activities selected may include, for example, picking, picking (ie gripping / removing, eg from a storage rack), checking, fastening. The assignment of activities to 1520 to share 1510 corresponds to a second selection B or a second assignment B. Of course, each part more than one activity can be assigned.

By means of a third selection C can the activities 1520 workstations 1530 be assigned, ie places in a manufacturing plant, where the corresponding activities are to be exercised. For example, it may be determined that the selected first activity 1522 in relation to the first part 1512 at a first workstation 1532 should be exercised. For example, it can be determined in the exemplary scenario on which workstation on a production line the rearview mirror can be mounted in the vehicle. Typically, each instance of an activity is assigned exactly one workstation. However, it may be that an activity may fall into several steps, so each substep is assigned to another workstation. In the exemplary scenario, this means that the rearview mirror is usefully mounted on a workstation.

After the assignment of activities 1522 to workstations 1530 Finally, by means of a fourth selection D the activities 1530 resources 1540 be assigned. In 15 you see that the first activity 1536 , which is the first workstation 1532 has been assigned (therefore the dashed box - this indicates an already assigned activity), a first resource 1542 is assigned, for example, a screwdriver. Each activity from the group of activities 1530 can be at least one resource from the group of resources 1540 be assigned.

Each selection AD can also be understood as an assignment. A corresponding program implementation can be realized for example via drop-down menus or by "drag-and-drop" function. Each of the objects in the different groups 1510 - 1540 may have parameters which are adjustable and determine the possible amount of choices for a particular selection AD. For example, to an xth activity 1536 which is a y-th workstation 1534 has been assigned, only resources are displayed, which are actually present at this workstation / can be used or which in the context of this x-th activity 1536 stand.

The special feature of the process sequence taking place in the production process platform according to the invention 1500 is that processes from logistics and production can be planned directly next to each other without any separation. This can happen, for example, with the umpteenth activity 1524 a logistic action, for example, the delivery of the first part 1512 in a certain storage rack (which would then be associated as associated resources), or even one from the production, such as said mount the rearview mirror in a vehicle (with the screwing means used as the associated equipment from the group of resources 1540 would be assigned). In the context of the method according to the invention, the activities and resources are abstractly considered and allocated to parts during planning and distributed to workstations. It should be understood that the illustrated selections AD may be made in a different order or may link together entirely different sets of objects. For example, the parts of the group of parts 1510 initially workstations 1530 can be assigned or it can be the activities 1520 first the appropriate resources 1540 be assigned and the activities 1520 can then be subsequently to the workstations 1530 be distributed.

After planning according to the described process flow 1500 a simulation can be performed to check the planned operating condition for consistency. The planned configuration can be transferred to the resources, so that the production can proceed as planned. During the course of production, data from the production level can be transmitted to the process production platform, thus the parameters of the objects in the groups 1510 - 1540 to keep up to date.

Within the scope of this description there is also provided a computer program (ie, a collection of instructions executable by a computing device) for manufacturing a product, the computer program being arranged to perform the inventive method when executed on a data processing device coupled to corresponding production factors performs.

Also provided is a computer program product comprising executable program code, the program code executing the inventive method when executed by a data processing device coupled to corresponding production factors. The computer program product may be any medium that stores permanently or remotely computer readable instructions.

Furthermore, also with particular reference to the accompanying figures, there is also provided a data processing apparatus on which the computer program according to the invention is provided, and which is coupled to corresponding production factors necessary for carrying out the method described herein.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited non-patent literature

• VDI Guideline 2815 [0079]

Claims (11)

A method of manufacturing a product, wherein the product is a functional unit composed of at least two parts, each of which is in a separate location, the method comprising: at least one logistics process in which a part is transported from its location to the place of need; and at least one production process, in which the part is assembled with at least one further part at the place of requirement, the method being planned and / or simulated in its entirety before and during its execution in a first electronic data processing program and / or directly controlled by a second electronic data processing program, with direct control of a group of production factors, which employees and / or resources and / or material. The method of claim 1, wherein the first electronic data processing program is identical to the second electronic data processing program. The method of claim 1 or 2, wherein the set of production factors further comprises data. Method according to one of claims 1 to 3, wherein at least one instance is associated with each physical object involved in the method of manufacturing a product in the first electronic data processing program and / or in the second electronic data processing program. The method of claim 4, wherein each physical object involved in the method of manufacturing a product is assigned an address, which is preferably based on the Internet Protocol. A method according to any one of claims 1 to 5, wherein the first electronic data processing program and / or the second electronic data processing program has an appropriate programming interface for each physical object involved in the method of manufacturing a product. The method of claim 5, wherein each physical object is associated with at least one instance via its address. A method according to claim 4 or 5, wherein the overall direct control of the method by the second electronic data processing program is on the basis of process information transmitted from the physical objects to the instances in real time. Computer program for producing a product, wherein the computer program is set up so that when executed on a data processing device which is coupled to corresponding production factors, the method according to one of claims 1 to 8 executes. A computer program product comprising executable program code, the program code executing the method of any one of claims 1 to 8 when executed by a data processing device coupled to respective production factors. Data processing device on which the computer program according to claim 9 is executively provided, and which is coupled to corresponding production factors.

Images