A typical challenge for today's companies is to resolve external changes and fluctuations with existing factory structures. If the existing structures reach their limits, deficits need to be eliminated through targeted replanning. Small and medium-sized enterprises (SMEs) in particular usually have historically evolved machine and plant fleets, which means that questions about an optimal factory layout are increasingly arising.

Stamer Musikanlagen, based in Sankt Wendel, Germany, was also concerned with such a question, and its sales figures have developed positively since the company was founded. At the same time, the structures in the individual production areas have grown accordingly. The Mittelstand 4.0 Competence Center Saarbrücken supported the company in increasing the efficiency of its existing production processes and expanding its capacities. Using a four-stage approach, the existing layout and material flows were analyzed and optimized. Modern digital tools for factory planning and material flow simulation were used to create and analyze models of various scenarios. A migration strategy can be derived from these scenarios. This strategy transparently shows which measures need to be taken in order to gradually restructure the factory.

Data collection and creation of virtual models
The first step is to collect the information available in the real factory that is required for modeling in the factory planning and material flow software. In general, both product data and the associated process information are collected. In addition, information on machines and systems as well as on the existing boundary conditions, for example of a structural or organizational nature, are also part of the initial database.

Once the data has been collected, the factory planning software can be used in the second step to process the information transparently and clearly. A static factory model can be created in the software by mapping the existing machines and systems and storing the process chains of the product variants to be manufactured. The necessary transport of components within production results in material flows, which are visualized in the software as a "Sankey diagram" and quantified with transport indicators based on the distances covered. In the Sankey diagram, flows are represented by arrows with a width proportional to the quantity, so that particularly transport-intensive routes in production are immediately visible.

The current structure of the factory under investigation, also known as "Brownfield As Is", is used as a reference to assess other scenarios in terms of their material flow. In contrast, there is an ideal factory layout, the "greenfield" scenario, which is developed independently of the given boundary conditions. In the greenfield, machines and systems are arranged in such a way that a minimum transportation ratio is achieved. An attempt is then made to bring the existing layout as close as possible to the greenfield scenario, taking into account the given restrictions ("brownfield best practice"). To implement the brownfield best practice scenario, changes must inevitably be made to the current layout. If these changes cannot be implemented at short notice and without disrupting production, the challenge is to find a migration path in which the layout is adapted in stages. In the individual migration stages, measures are only implemented to a limited extent, which means that ongoing production is only affected for a short time or to a tolerable extent.

Once a migration path has been created, material flow simulations are carried out to further test and validate the scenarios created. This process is also supported by software. In the simulation environment, the necessary process times and production programs are also used to ensure dynamic mapping of production. Depending on the complexity of the model, various types of information can be obtained from this. For example, bottlenecks in production become visible through critical states in machine utilization diagrams. In addition, exact employee requirements are also determined when using human models. By using optimization tools, input data such as the production plan is also optimized. If the simulation of the individual scenarios reveals problems, the affected scenarios are adapted and tested in the factory planning environment until a migration path that can be implemented without any problems is found. Finally, this migration path is gradually implemented in the real factory.

A migration path was developed in the project with Stamer, the first changes to which will be implemented during the upcoming company vacations.

Prof. Dr. R. Müller; L. Hörauf; J. Koch / as

Center for Mechatronics and Automation Technology gGmbH (ZeMA)

Briefly explained: The ZeMA:
The Center for Mechatronics and Automation Technology gGmbH (ZeMA) conducts application-oriented research and industry-related development in the fields of sensor and actuator technology, manufacturing and assembly processes and their automation. ZeMA offers a broad spectrum of research with the aim of industrialization and the transfer of research and development results to industry and to the store floor. Its work focuses on mechatronic systems, innovative production technologies and Industry 4.0 applications. ZeMA works closely with the institutes and chairs of Saarland University of Applied Sciences (htw saar) and Saarland University (UdS) to carry out its development activities . www.zema.de

Mittelstand 4.0 Competence Center Saarbrücken

In addition to implementation projects, the Mittelstand 4.0 Competence Center Saarbrücken offers free and vendor-neutral services for SMEs in the fields of production networking, human-technology interaction, digital business models and digital craftsmanship. These services include information events, workshops and testing opportunities using demonstrators. www.kompetenzzentrum-saarbruecken.digital

Scientific Society for Assembly, Handling and Industrial Robotics (MHI e.V.)

Briefly explained: The MHI e.V.
The Wissenschaftliche Gesellschaft für Montage, Handhabung und Industrierobotik e.V. (MHI e.V.) is a network of renowned university professors - institute directors and chair holders - from German-speaking countries. The members conduct both fundamental and application-oriented research on a wide range of current topics in the fields of assembly, handling and industrial robotics. Further information on the society, its members and activities: http://www.wgmhi.de.