Abstract

The combination of lean production and Industry 4.0 exhibits excellent potential in advancing operations management and, especially, production control. This improvement potential is applicable to the semi-process industry (S-PI), as higher product variety and higher demand variability require greater flexibility from production systems. This flexibility is difficult to achieve in S-PI environments, in which it is imperative to cope with the long setup times and stability needed for the high utilization requirements. Heijunka addresses this stability-flexibility paradox but was designed for short setup times and is thus considered not directly applicable. In this article, we use design science research to adapt Heijunka to the S-PI and combine it with cyber-physical systems technologies. The developed production control concept, every product every cycle (EPEC) 4.0, aims to schedule the production system as efficiently as possible, providing the necessary flexibility and minimum schedule perturbation. Furthermore, we present the findings from a validation case study within the automotive supply industry.

摘要

精益生产和工业 4.0 的结合在推进运营管理，尤其是生产控制方面展现出巨大的潜力。这种改进潜力适用于半加工行业 (S-PI)，因为更高的产品种类和更高的需求可变性要求生产系统具有更大的灵活性。这种灵活性在 S-PI 环境中很难实现，在这种环境中，必须应对高利用率要求所需的较长设置时间和稳定性。Heijunka 解决了这种稳定性-灵活性悖论，但设计用于较短的设置时间，因此被认为不直接适用。在本文中，我们利用设计科学研究使 Heijunka 适应 S-PI，并将其与网络物理系统技术相结合。发达的生产控制理念，每个产品每个周期 (EPEC) 4.0 旨在尽可能高效地安排生产系统，提供必要的灵活性和最小的进度干扰。此外，我们还介绍了汽车供应行业验证案例研究的结果。