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Manufacturing System Optimization with Lean Methods, Manufacturing

Process Objectives and Fuzzy Logic Controller Design

Article  in  Procedia CIRP · July 2020

DOI: 10.1016/j.procir.2020.04.145

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Procedia CIRP 00 (2017)
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53rd
53rd CIRP
CIRP Conference
Conference on
on Manufacturing
Manufacturing Systems
Systems
53rd CIRP Conference on Manufacturing Systems
Manufacturing System Optimization with Lean Methods, Manufacturing
Manufacturing
ProcessSystem
28th CIRPOptimization
Design Conference,with
Objectives and Fuzzy Lean
May 2018,
Logic Methods,
Nantes,
Controller
France Manufacturing
Design
Process Objectives and Fuzzy Logic Controller Design
A new methodology to a,∗analyze
Tom Drews the functional
, Paul Molenda b,c
, Oliver Oechsle and cphysical
, Jan Kollerarchitecture
c of
existing products for Freelance
an, assembly oriented product family
Kolleridentification
a,∗ b,c c c
Tom Drews Paul Molenda
Researcher, , Oliver
a
Am Höllenberg Oechsle
14, 07589 , Jan
Bocka, Germany
b University of Bayreuth, Chair Manufacturing and Remanufacturing Technology,
a Freelance Researcher, Am Höllenberg 14, 07589Universitätsstrasse
Bocka, Germany 30, 95447 Bayreuth, Germany
c Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Universitätsstrasse 9, 95447 Bayreuth, Germany
b University
c Fraunhofer Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
of Bayreuth, Chair Manufacturing and Remanufacturing Technology, Universitätsstrasse 30, 95447 Bayreuth, Germany
Institute for Manufacturing Engineering and Automation IPA, Universitätsstrasse 9, 95447 Bayreuth, Germany
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
*Abstract
Corresponding
This author.an
paper presents Tel.: +33 3 87for
approach 37 the
54 30; E-mail address:
integration of lean paul.stief@ensam.eu
methods and manufacturing process objectives through the usage of a fuzzy logic
controller. The fuzzy logic controller comprises twelve
This paper presents an approach for the integration of lean methods common lean and
methods, three manipulated
manufacturing variables (setup
process objectives through time,
the error
usagerate
of and technical
a fuzzy logic
availability) and five manufacturing process objectives, which are operationalized through the target variables Every
controller. The fuzzy logic controller comprises twelve common lean methods, three manipulated variables (setup time, error rate and technical Part Every Interval (EPEI),
Overall Equipment
availability) and fiveEffectiveness
manufacturing (OEE), Lead
process Time (LT),
objectives, Quality
which Grade (QG) andthrough
are operationalized DeliverytheService
target (DS). TheEvery
variables basic Part
structure
EveryofInterval
the fuzzy logic
(EPEI),
Abstract
controller design and
Overall Equipment the modeling(OEE),
Effectiveness of the Lead
optimization
Time (LT),effect on theGrade
Quality manufacturing
(QG) andprocess
Deliverylevel is shown.
Service (DS). The basic structure of the fuzzy logic
controller
In design and
today’s business the modelingthe
environment, oftrend
the optimization
towards more effect on thevariety
product manufacturing process level
and customization is shown. Due to this development, the need of
is unbroken.
c 2020 The Authors. Published by Elsevier B.V.

agile
© 2020andThereconfigurable production
Authors. Published systems B.V.
by Elsevier emerged to cope with various products and product families. To design and optimize production
This
c 2020
 is an open
The accessPublished
Authors. article under
by the CC BY-NC-ND
Elsevier B.V. matches, license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
This
systems is an
as open
well access
as article the
to choose under the CC
optimal BY-NC-ND
product license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
product analysis methods are needed. Indeed, most of the known methods aim to
Peer-review
This is an
Peer-review under
open responsibility
access
under article
responsibility of
underof the
the
the scientific
CC committee
BY-NC-ND
scientific of
license
committee ofthe 53rd CIRP
CIRPConference on
onManufacturing
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
the 53rdproduct Conference Manufacturing Systems.
analyze a product or one product family on the physical level. Different families, however, may differ Systems
largely in terms of the number and
Peer-review
nature under
of components. responsibility
This of
fact Lean the
impedes scientific committee
an efficient of the
comparison 53rd CIRP Conference on Manufacturing
and choice of appropriate product family Systems.
combinations for the production
Keywords: Manufacturing System; Methods; Fuzzy; Process; Optimization
system.
Keywords: A new methodology
Manufacturing is proposed
System; to analyze
Lean Methods; Fuzzy;existing
Process;products in view of their functional and physical architecture. The aim is to cluster
Optimization
these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable
assembly systems. Based on Datum Flow Chain, the physical structure of the products isthe
nowadays, analyzed. Functional
optimization subassemblies
potential for an are identified, and
objective-driven
a1.functional analysis
Introduction is performed. Moreover, a hybrid functional and physical architecture
implementation
nowadays, graph (HyFPAG)
of lean methods
the optimization is the output
is estimated
potential which
to be depicts the
very high
for an objective-driven
similarity between product families by providing design support to both,[1]. production system
Studies show planners and product designers. An illustrative
1. Introduction implementation of that
lean 50% of the
methods productivity
is estimated difference
to be very highto
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
The globally increasing competition among manufacturing the best
[1]. competitor
Studies show that is explained
50% of the by the wrong implementation
productivity difference to
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
companies
TheThe mainly
globally arises from
increasing major changes in the market and of
thelean
bestmethods
competitor [6].isInexplained
60% of the by companies, the operational
the wrong implementation
© 2017 Authors. Publishedcompetition
by Elsevier B.V. among manufacturing
customer perspective.
companies
Peer-review mainly
under arises These
fromof
responsibility changes
major include
changes
the scientific ine.the
g. market
committee increasing
of theand
28th CIRP and strategic
of lean
Design methodsobjectives
Conference[6]. 2018.are not aligned and
In 60% of the companies, the thus hampering the
operational
product variants,
customer perspective. shorter product
These changeslifecycles,
include new technologies
e. g. increasing objective-driven
and strategic objectives implementation of leanand
are not aligned methods [9]. Addition-
thus hampering the
and digitalization.
product
Keywords: variants, Thesemethod;
Assembly; shorter
Design external
product drivers of transformability
lifecycles,
Family new technologies
identification are ally, only 10% of the lean methods are fully
objective-driven implementation of lean methods [9]. Addition- implemented [10].
significantly
and influencing
digitalization. today’s manufacturing
These external companies and
drivers of transformability are ally,Therefore,
only 10%this paper
of the leanpresents
methods an are
approach for the integration
fully implemented [10].
the production perspective (see Fig. 1). [1,
significantly influencing today’s manufacturing companies and 2, 3] of twelve
Therefore, this paper presents an approach for and
qualitatively described lean methods five quan-
the integration
theAccording
productiontoperspective
Westkämper, (see manufacturing
Fig. 1). [1, 2, 3]companies have titatively
of twelve measurable
qualitativelymanufacturing
described leanprocess methods objectives
and five(targetquan-
1.two
Introduction
possibilities to cope with the external
According to Westkämper, manufacturing companies have drivers of transforma- of the
variables)product
through range the and
usage characteristics
of a fuzzy logic
titatively measurable manufacturing process objectives (target manufactured
controller. and/or
bility, namely, product
two possibilities to copeand process
with innovations
the external drivers[4]. For process
of transforma- assembled in this system.
variables) through the usage In this
of acontext,
fuzzy logic the controller.
main challenge in
Due
innovation, to thethedesign fast development
and redesign in the
(optimization)
bility, namely, product and process innovations [4]. For process domain
of manufac- of modelling and
Market and analysis
customer is now
perspective not
(external only
driversto cope with single
of transformability)

communication
turing processes and
and an ongoing
systems is the trend
most
innovation, the design and redesign (optimization) of manufac-of digitization
essential element and
to products,Marketaand
Increasing
limited
product
customer product
variant
Shorter product lifecycles
mixes
range
perspective or existing
Increasing
(external costsofand
drivers product families,
quality pressure
transformability)
New technologies and digitalization
digitalization,
cope with the manufacturing
external drivers enterprises
of are
transformability
turing processes and systems is the most essential element to facing[5, important
6]. but also to be
Increasing
Heterogeneousable
product
andto analyze
variant
global
Shorter product lifecycles
mixes
marketsand to compare
Increasing
Demographic costs
products
and
change quality
to define
pressure
and scarcity
New technologies and digitalization
challenges
For the in today’s
effectiveness market
of environments:
optimization
cope with the external drivers of transformability [5, 6]. activities,a continuing
it is of ut- new product families.
Heterogeneous and It
global can be
markets observed
Demographic that
changeclassical
Production perspective (internal drivers of transformability) and existing
scarcity
tendency
most towards
Forimportance
the reduction
effectiveness of of
to implement product development
lean methods
optimization ittimes
is ofand
in accordance
activities, ut- product families
Production are regrouped
perspective in function
(internal of clients
Manufacturing
drivers or features.
processes
of transformability)
Products
shortened
with the product
objectives lifecycles.
of In addition,
manufacturing
most importance to implement lean methods in accordance there
companies is an
[6,increasing
7]. Only However, assembly oriented product Manufacturing processes to find.
families are
and systems hardly
Products
demand
the of customization,
objective-driven being
implementation at the
of
with the objectives of manufacturing companies [6, 7]. Onlysame
lean time
methods in a global
leads to On
Assemblytheandproduct family
Product level, products
Work materials differ
Process
and systems mainly in and
Machines two
component innovations and constructions innovations means of prod.
competition
effective with
optimization competitors
of all over
manufacturing the
the objective-driven implementation of lean methods leads to world.
systems This
[6, 8]. trend,
Even main characteristics:
Assembly and Product(i) theWork number of
materials components
Process and (ii)
Machines the
and
component Integration of design and constructions
innovations Manufacturing engineering
innovations means of prod.
which is inducing the development from
effective optimization of manufacturing systems [6, 8]. Even macro to micro type of components and (e.g.
function mechanical, electrical,
and electronical).
technologies
Integration of design Manufacturing engineering
markets, resultsauthor.
∗ Corresponding in diminished lot sizes due to augmenting Classical methodologies
and function consideringand mainly single products
technologies
product
∗ E-mail varieties
address: (high-volume to
tom.drews@uni-bayreuth.de
Corresponding author. low-volume
(Tom production)
Drews). [1]. or
Fig. solitary,
1. External already
and internal existing
drivers of product families
transformability and analyze
sources the
of produc-
tion
Fig. innovations according
To cope
E-mail with
address:thistom.drews@uni-bayreuth.de
augmenting variety as (Tomwell as to be able to
Drews). product structure
1. External and on a to
internal Westkämper
physical
drivers of level[1] based on and
(components
transformability [4, 7, 11, 12,of13]
level) which
sources produc-
identify
2212-8271 possible
c 2020 The optimization
Authors. Publishedpotentials in the existing
by Elsevier B.V. tion innovations
causes accordingregarding
difficulties to Westkämper an[1]efficient
based on [4,definition
7, 11, 12, 13] and
This is
productionan
2212-8271  open access
c system,
2020 The it article under the
is important
Authors. CC BY-NC-ND
Publishedtobyhave license
a precise
Elsevier B.V. (http://creativecommons.org/licenses/by-nc-nd/4.0/)
knowledge comparison of different product families. Addressing this
Peer-review under
This is an open responsibility
access of the
article under the scientific committee
CC BY-NC-ND of the
license 53rd CIRP Conference on Manufacturing Systems.
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
2212-8271 ©
Peer-review 2020responsibility
under The Authors. Published
of the scientificby Elsevier of
committee B.V.
the 53rd CIRP Conference on Manufacturing Systems.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th 53rdDesign
CIRP Conference
Conference2018.
on Manufacturing Systems
10.1016/j.procir.2020.04.145
 Tom Drews et al. / Procedia CIRP 93 (2020) 658–663 659
Tom Drews et al. / Procedia CIRP 00 (2019) 000–000 2

2. Manufacturing systems, lean methods and objectives Tab. 1. Twelve common lean methods and the corresponding principles

Lean method Principle

2.1. Manufacturing systems and lean methods
1. 5S (M5S) Standardization
The relationship of output to input is significant for the pro- 2. Andon (MAN) Visual management
ductivity (efficiency) of a manufacturing process and thus the 3. Heijunka (MHE) Pull principle
4. Kanban (MKA) Pull principle
entire manufacturing system. One major possibility to improve 5. One Piece Flow (MON) Flow principle
the productivity of manufacturing processes is the correct usage 6. Poka Yoke (MPO) Zero defects principle
of design and optimization (lean) methods.1 Other design and 7. Processstandardization (MPR) Standardization
optimization approaches include the appropriate usage of mate- 8. Shopfloormanagement (MSH) Visual management
rials and manufacturing technologies as well as the capabilities 9. Single Minute Exchange of Die (MSM) Flow principle
10. Total Productive Maintenance (MTP) Zero defects principle
of the employees. [15] 11. Waste Evaluation (MVE) Avoidance of waste
When looking at design and optimization methods within 12. Employee Suggestion System (MVO) Avoidance of waste
lean manufacturing, there are specific terms such as (lean) con-
cepts, principles, methods and tools.2 These terms are all me-
2.2. Manufacturing objectives
thodical design approaches which can be differentiated by their
level of abstraction and level of operationalization (see Fig. 2).
Objectives describe future states, which are considered to
Aggregation of methodical design approaches & Effects of methods on productivity be desirable. Usually, objectives are derived from superordinate
&
strategies or visions, which manufacturing companies want to
Manufacturing
High

Concepts
system achieve. The usage of objectives implies actions to achieve the
Level of abstraction

Principlesa
desired future state. [30, 31]
Effect range

Division or
Principles
Medium

department The modern understanding of manufacturing systems dif-

Methods
Machine or ferentiates strategic and operational manufacturing objectives
work placec
[32, 33]. Furthermore, the objectives and their target variables
Low

Tools Methodsb
Method 1
Manufacturing
process
(operationalization of objectives) are embedded in various con-
Method 2
Effect intensity
trol systems for the effective and objective-driven management
Low Medium High
Level of operationalization Effect range and effect intensity Effect level of manufacturing systems. Ultimately, the target variables serve
as manipulated and/or controlled variables on the process level
Fig. 2. Principles and methods as design and optimization approaches for the
and are derived from different layers within manufacturing
productivity of manufacturing systems [1], a Principles are mainly derived from
a lean perspective [14]. b Methods comprise lean methods and other optimiza- companies (see Fig. 3). [13, 34]
tion methods. c This level is also known as work system in REFA [18].
Four layers of the control system model for the mgmt. of manufacturing sys.

In accordance with the VDI-Guideline 2870 these four terms 1. Normative management
Corporate culture, goals, principles, rules and philosophy
can be aggregated to the two terms ”principles” and ”methods”
[14]. As shown in Fig. 2, the methods have varying optimization Objectives & interest of stakeholder
2. Strategic management
effects on the different levels of the vertical structure of manu- Strategic corporate planning and definition of business units
facturing systems and thus on the manufacturing process itself.
Strategic manufacturing objectives
The effect can vary in range and intensity. Furthermore, meth- 3. Strategic manufacturing mgmt.
ods can be assigned to various principles as shown exemplarily Strategic design of manufacturing systems and strategic planning

in Tab. 1. The twelve methods shown in Tab. 1, are the basis Operational manufacturing objectives
4. Operational manufacturing mgmt.
for the analyses and approach presented in the paper at hand. Operational manufacturing planning, control and monitoring
The methods are the most common denominator among scien- Manipulated variables Controlled variables
tific approaches as well as industrial applications.3 Thus, they (target values) (actual values)
can be found in international guidelines like VDI and REFA
Work system
[14, 23], industrial handbooks [24, 25], scientific publications Manufacturing process
[26, 27] and academic research [28, 29]. The results of the de- Input Throughput Output
tailed analyses and evaluation of the lean methods is shown in
section 3. Fig. 3. Objectives and target values within the control system model for the
management of manufacturing systems [1] based on [13, 34, 35]
1
The terms ”lean methods” and ”methods” are used as synonyms. The ma-
jority of the technical terms is based on the VDI-Guideline 2870 for lean pro- As shown in subsection 2.1 (see Fig. 2), lean methods are
duction systems [14]. affecting manipulated variables of manufacturing processes and
2 The authors of the paper at hand acknowledge that the term ”lean” is more
thus optimizing the output-input relationship. The effectiveness
than just the implementation of (single) methods, thus also referring to thinking can be measured with actual values (controlled variables).
principles, philosophies of working and organizing as well as the well-known
Toyota Production System (TPS) [16, 17].
A great many objectives for manufacturing systems are used
3 The results of comprehensive empirical studies, e. g. from Rivera et al. and in the scientific community and within actual manufacturing
Shah et al., are part of the method selection process [19, 20, 21, 22]. companies today. A major part of the research conducted by
2
660 Tom Drews et al. / Procedia CIRP 93 (2020) 658–663
Tom Drews et al. / Procedia CIRP 00 (2019) 000–000 3

the authors of the paper at hand dealt with empirical studies lean methods as well as the time horizon addressing the real-
and combined scientific approaches from a decision theory and ization within a manufacturing system. These aspects are also
operations management background. For the sake of simplicity widely covered in industrial handbooks or benchmarks for the
and the purpose of the paper at hand, Tab. 2 shows the five de- implementation of lean methods. Tab. 4 summarizes the evalu-
rived manufacturing process objectives and their corresponding ation concerning these aspects and illustrates the results in the
target variables, as one result of the conducted research.4 last three columns.
Tab. 2. Five manufacturing process objectives (first level means objectives) and
Tab. 4. Evaluation of lean methods regarding training effort, operation effort
target variables for the fundamental objective ”maximize performance” [1, 37]
and realization [1] based on [23, 24, 27, 39]
KUF = Short-term Existing evaluations of methods This Paper
Manufacturing process objective Target variable MIF = Mid-term
Training effort Operation effort Realization

Operation effort
LAF = Long-term

Ttraining effort
Maximize flexibility Every Part Every Interval (EPEI) n/a = Not available

Realization
 = High
Maximize availability Overall Equipment Effectiveness (OEE)  = Medium
Maximize efficiency Lead Time (LT)  = Low

[27]

[24]

[23]

[27]

[24]

[23]

[27]

[39]

[23]
# Methods
Maximize effectiveness Quality Grade (QG) 1. 5S (M5S)       KUF KUF MIF   KUF
Maximize delivery performance Delivery Service (DS) 2. Andon (MAN)       KUF MIF KUF   KUF
3. Heijunka (MHE)  n/a   n/a  KUF MIF LAF   MIF
4. Kanban (MKA)       LAF MIF LAF   LAF
The five manufacturing process objectives of Tab. 2 are the 5. One Piece Flow (MON)  n/a   n/a  LAF LAF LAF   LAF
6. Poka Yoke (MPO)       KUF KUF KUF   KUF
first level of means objective for the fundamental objective 7. Processstandardization (MPR)       LAF LAF MIF   LAF
8. Shopfloormanagement (MSH) n/a   n/a   n/a KUF MIF   MIF
”maximize performance”. Other exemplary fundamental objec- 9. Single Min. Exchange of Die (MSM)       KUF KUF MIF   KUF
tives are ”minimize costs” or ”maximize sustainability”, which 10. Total Productive Maint. (MTP)       MIF MIF MIF   MIF
11. Waste Evaluation (MVE) n/a   n/a   n/a KUF MIF   MIF
would yield in other manufacturing process objectives and cor- 12. Employee Suggestion Sys. (MVO)       KUF KUF KUF   KUF
responding target variables.
The five target variables EPEI, OEE, LT, QG and DS repre- The last step of the evaluation is the introduction of a five-tier
sent the most common operationalization of the manufacturing maturity model for the description of the methods. The levels of
process objectives and are often used as Key Performance Indi- maturity are ”initial”, ”planned”, ”defined”, ”measurable” and
cators (KPI).5 The five target variables are furthermore a com- ”optimizing”.6 A five-tier maturity model for the qualitative de-
bination of various controlled variables of the manufacturing scription of lean methods is proven within scientific approaches
process, as shown in Fig. 3, and are influenced by the manipu- for manufacturing systems and is usually derived from the Ca-
lated variables. The relationship of the five target variables and pability Maturity Model Integration (CMMI) [3, 40, 41, 42].
three manipulated variables (setup time, error rate and technical
availability) is shown in section 4.
4. Fuzzy logic controller design

3. Evaluation of lean methods 4.1. Structure of the fuzzy logic controller

The evaluation of lean methods focuses on finding qualita-
tive interdependencies, which can be used for the design of the
fuzzy logic controller (rule sets) in section 4. On the basis of the
analyses of Aull, Gerberich and Hines et al., the qualitative
interdependencies, shown in Tab. 3, are derived [26, 28, 29].
Tab. 3. Qualitative interdependencies between lean methods [1]
 = Strong interdependence
 = Medium interdependence
= Low interdependence
The design of the fuzzy logic controller is based on the ob-
servation, that a lot of aspects of lean methods are only de-
scribed qualitatively. Whereas the manufacturing process ob-
jectives, if derived and operationalized with appropriate target
variables, are quantitative in the majority of cases. The struc-
ture of the fuzzy logic controller as well as the input and output
Methods parameters are shown in Fig. 4.
12. MVO

e c t on
11. MVE
10. MTP


5. MON

9. MSM
6. MPO

ef
3. MHE

8. MSH
2. MAN

4. MKA

7. MPR
1. M5S

 = No immediate interdependence Input Fuzzy logic controller Output

# Methods parameters Second subsystem of the fuzzy logic controller parameters
1. 5S (M5S)            Fuzzification Inference Defuzzification
2. Andon (MAN)            Methods
First subsystem of the fuzzy logic controller
3. Heijunka (MHE)             Twelve methods
 Five levels of Fuzzification Inference Defuzzification
4. Kanban (MKA)           
maturity
𝜇𝜇(𝑥𝑥 )
1
Rule R1: 𝜇𝜇(𝑦𝑦 ) 1
Optimization
5. One Piece Flow (MON)            1 1
IF … AND … effects
Poka Yoke (MPO)
0,5
6.
0,5
           THEN …
Processstandardization (MPR) Realization 0 𝑥𝑥
 Setup time
7.
1
0 𝑦𝑦
           1

Shopfloormanagement (MSH)  Short-term  Error rate

8.            𝜇𝜇(𝑥𝑥2 )
Rule R2: 𝜇𝜇(𝑦𝑦2 )

 Technical
1

Single Minute Exchange of Die (MSM)  Mid-term 1

9.            0,5 IF … AND …
 Long-term 0,5
availability
10. Total Productive Maintenance (MTP)            0 𝑥𝑥2 THEN … 0 𝑦𝑦2

11. Waste Evaluation (MVE)            … …

Maturities 𝜇𝜇(𝑦𝑦𝑙𝑙 )
12. Employee Suggestion System (MVO)            𝜇𝜇(𝑥𝑥𝑛𝑛 )
1
 Setup time 1
Rule Rm: 0,5

 Error rate 0,5

IF … AND … 0 𝑦𝑦𝑙𝑙
 Technical
Besides the qualitative interdependencies, the paper at hand
0 𝑥𝑥𝑛𝑛
THEN …
availability
also considers the effort for the training and operation of the
Fig. 4. Fuzzy logic controller structure for the determination of a quantitative
4
optimization effect [1], fuzzy logic principles based on [43, 44, 45, 46, 47]
Publications of the conducted research are [1, 27, 36, 37, 38].
5 Other target variables or KPI are also possible. 6 A more detailed evaluation of each level and method is shown in [1].
3
 Tom Drews et al. / Procedia CIRP 93 (2020) 658–663 661
Tom Drews et al. / Procedia CIRP 00 (2019) 000–000 4

The input parameters comprise the twelve lean methods with basis for the calculation of the optimizing effect on the manip-
five maturity levels, the time-dependable realization of the lean ulated variable setup time. The optimizing effect on the manip-
methods (see last column in Tab. 4) and the maturity of the ma- ulated variables error rate and technical availability is based on
nipulated variables (setup time, error rate and technical avail- the aggregated maturity level (AML) of the method Total Pro-
ability). The input parameters are used in two subsystems of ductive Maintenance (MTP).8
the fuzzy logic controller. The first subsystem accounts for 296
0 1 : I F AML−MSM IS LO AND ML-ST IS LO AND RT IS ST
fuzzy (implication) rules (seven bases of rules), upon the qual- THEN OPE-MSM-ST IS HI ; / / High
itative interdependencies shown in Tab. 3. Fig. 5 shows an ex- 0 2 : I F AML−MSM IS MO AND ML-ST IS LO AND RT IS ST
THEN OPE-MSM-ST IS VH ; / / VeryHigh
cerpt from the rule base for the determination of the total matu- 0 3 : I F AML−MSM IS HI AND ML-ST IS LO AND RT IS ST
rity level (TML) of the method Single Minute Exchange of Die THEN OPE-MSM-ST IS VH ; / / VeryHigh
0 4 : I F AML−MSM IS LO AND ML-ST IS MO AND RT IS ST
(MSM) in dependence of the maturity levels (ML) of dependent THEN OPE-MSM-ST IS MO ; / / Moderate
methods (M5S, MAN, MPR, MTP and MVO; see Tab. 3). 0 5 : I F AML−MSM IS LO AND ML-ST IS LO AND RT IS MT
THEN OPE-MSM-ST IS MO ; / / Moderate
0 6 : I F AML−MSM IS MO AND ML-ST IS LO AND RT IS MT
0 1 : I F ML-M5S IS LO AND ML-MAN IS LO AND ML-MPR IS LO AND
THEN OPE-MSM-ST IS HI ; / / High
ML-MTP IS LO AND ML-MVO IS LO THEN TML-MSM IS VL ; / / VeryLow
0 7 : I F AML−MSM IS HI AND ML-ST IS LO AND RT IS MT
0 2 : I F ML-M5S IS HI AND ML-MAN IS LO AND ML-MPR IS LO AND
THEN OPE-MSM-ST IS VH ; / / Very High
ML-MTP IS LO AND ML-MVO IS LO THEN TML-MSM IS VL ; / / VeryLow
0 8 : I F AML−MSM IS LO AND ML-ST IS MO AND RT IS MT
0 3 : I F ML-M5S IS LO AND ML-MAN IS HI AND ML-MPR IS HI AND
THEN OPE-MSM-ST IS LO ; / / Low
ML-MTP IS LO AND ML-MVO IS LO THEN TML-MSM IS LO ; / / Low
0 9 : I F AML−MSM IS LO AND ML-ST IS LO AND RT IS LT
0 4 : I F ML-M5S IS LO AND ML-MAN IS LO AND ML-MPR IS HI AND
THEN OPE-MSM-ST IS LO ; / / Low
ML-MTP IS HI AND ML-MVO IS LO THEN TML-MSM IS LO ; / / Low
1 0 : I F AML−MSM IS MO AND ML-ST IS LO AND RT IS LT
0 5 : I F ML-M5S IS HI AND ML-MAN IS HI AND ML-MPR IS LO AND
THEN OPE-MSM-ST IS MO ; / / Moderate
ML-MTP IS LO AND ML-MVO IS HI THEN TML-MSM IS MO ; / / Moderate
0 6 : I F ML-M5S IS LO AND ML-MAN IS LO AND ML-MPR IS HI AND
ML-MTP IS LO AND ML-MVO IS HI THEN TML-MSM IS MO ; / / Moderate Fig. 6. Excerpt from an exemplary rule base (10 of 54) within the second sub-
0 7 : I F ML-M5S IS LO AND ML-MAN IS HI AND ML-MPR IS HI AND system of the fuzzy logic controller on the basis of the aggregated maturity
ML-MTP IS LO AND ML-MVO IS HI THEN TML-MSM IS HI ; / / High levels (AML) of the dependent methods from the first subsystem of the fuzzy
0 8 : I F ML-M5S IS HI AND ML-MAN IS HI AND ML-MPR IS HI AND
ML-MTP IS LO AND ML-MVO IS HI THEN TML-MSM IS HI ; / / High logic controller, the maturity level of the setup time (ML-ST) and the realization
0 9 : I F ML-M5S IS LO AND ML-MAN IS HI AND ML-MPR IS HI AND time (RT) for the determination of the optimization effect (OPE) of the method
ML-MTP IS HI AND ML-MVO IS HI THEN TML-MSM IS VH ; / / VeryHigh Single Exchange of Die (MSM) on the setup time (ST)
1 0 : I F ML-M5S IS HI AND ML-MAN IS HI AND ML-MPR IS HI AND
ML-MTP IS HI AND ML-MVO IS HI THEN TML-MSM IS VH ; / / VeryHigh Within the second subsystem of the fuzzy logic controller,
Fig. 5. Excerpt from an exemplary rule base (10 of 32) within the first subsys-
aggregated versions of the methods Single Minute Exchange of
tem of the fuzzy logic controller on the basis of the maturity levels (ML) of five Die (MSM) and Total Productive Maintenance (MTP) are used,
dependent methods for the determination of the total maturity level (TML) of because the optimization effects of these methods on the three
the method Single Minute Exchange of Die (MSM) manipulated variables can easily be quantified by the usage of
The total maturity level (TML) is calculated for each of the empirical data (e. g. [48, 49, 50]). Thus the qualitative maturity
twelve methods. For the method Single Minute Exchange of level of the lean methods can be individually quantified depend-
Die (MSM), the calculation comprises 32 rules, since five meth- ing on the industry branch and manufacturing processes.
ods have a qualitative interdependence (effect) on MSM (see
Tab. 3) and each effect is formulated with the linguistic terms 4.2. Manufacturing process integration
high and low (25 = 32).7
The optimization effect on the output side of the fuzzy logic
The results of the first subsystem of the fuzzy logic con- controller represents a change in the three manipulated vari-
troller are used for the second subsystem, which defines the op- ables setup time, error rate and technical availability on the
timization effect on the three manipulated variables setup time, manufacturing process level. This can be achieved through
error rate and technical availability (output parameters). The the usage of the general input-throughput-output understanding
second subsystem contains 162 fuzzy (implication) rules with of manufacturing processes (see Fig. 3). The main theoretical
three bases of rules. Each of the three manipulated variables has background of such an understanding is the relationship of in-
its own rule base. The goal of the second subsystem of the fuzzy ventory/work in process (WIP), lead time (LT) and cycle time
logic controller is the quantification of the optimization effect (CT). This relationship is also known as Little’s Law within the
on the three manipulated variables. queuing theory (see Eq. 1). [51]9
On the one hand, this is done by calculating an aggregated W = 1/λ · L (1)
maturity level (AML) for the methods Single Minute Exchange
of Die (MSM) and Total Productive Maintenance (MTP). On 1/λ Expected time between two consecutive arrivals or cycle time
the other hand, the time-dependent realization (RT) of each L Expected number of units in a system or work in process
method and the maturity level (ML) of each of the three ma- W Expected time spent by a unit in the system or lead time
nipulated variable is considered. An excerpt from an exemplary The paper at hand uses this fundamental relationship on the man-
rule base of the second subsystem of the fuzzy logic controller ufacturing process level, to integrate the three manipulated variables
is shown in Fig. 6. The complete rule base of Fig. 6 builds the
8 Each of the three rule bases in the second subsystem has 54 rules.
7
The distribution of the other methods (number of rules) is: M5S (32), MAN 9 There is a close connection of Little’s Law to the Funnel Model and Logistic
(32), MPR (64), MVO (64), MSH (8) and MTP (64). Operating Curves by Nyhuis and Wiendahl [52].
4
662 Tom Drews et al. / Procedia CIRP 93 (2020) 658–663
Tom Drews et al. / Procedia CIRP 00 (2019) 000–000 5

setup time, error rate and technical availability through the cycle times DQ ps Demanded quantity of process ps
of single processes. This approach is based on the lean methodology EPEI ps Every part every interval for process ps
value stream design and its operationalization by Erlach [53]. The cal- MQ ps Manufactured quantity of process ps
culations of the cycle time are shown in Eq. 2 to Eq. 7 [53]. OEE ps Overall equipment effectiveness for process ps
PR ps Performance rate of process ps
GR NE ST QL UP
CT ps = CT ps + CT ps + CT ps + CT ps (2) QG ps Quality grade of process ps
NE PT var, ps OT var, ps QR ps Quality rate of process ps
CT ps = = (3) WIP ps Work in process for process ps
RS ps OQvar, ps · RS ps
i
ST NE S T var, ps PCEvar, ps
CT ps = CT ps · · i (4) The optimization effect of the fuzzy logic controller on the three
LS var, ps · PT var, ps 
var=1 PCEvar, ps manipulated variables setup time, error rate and technical availability,
var=1
QL NE
as well as the calculation of the five target variables, can be done for
CT ps = CT ps · ER ps (5) multiple manufacturing processes. This enables also the analyses of
 
UP
CT ps = T T ps · 1 − T A ps (6) process chains in terms of entire manufacturing systems.
WD ps · WT ps
T T ps = (7)
i 5. Conclusion and outlook
PCEvar, ps
var=1
The paper at hand presents an approach for the integration of lean
GR
CT ps Gross cycle time of process ps methods and manufacturing process objectives through the usage of
NE
CT ps Net cycle time of process ps a fuzzy logic controller. The usage of common and well-known tar-
QL
CT ps Time losses through quality defects of process ps get variables, manipulated variables and lean methods, makes the ap-
ST
CT ps Time losses through setup time of process ps proach very suitable for the industrial application within manufac-
UP
CT ps Time losses through breakdowns of process ps turing companies. Furthermore, it is possible to integrate company-
ER ps Error rate of process ps specific maturity levels and individual manufacturing process data.
LS var, ps Lot size of variant var of process ps The approach could also be used for the integration of ecological
OT var, ps Operating time of variant var of process ps and economic aspects and analyses within a supply chain. Further fu-
OQvar, ps Operating quantity of variant var of process ps ture research could also focus on additional aspects concerning the
PCEvar, ps Pieces of variant var of process ps management of manufacturing systems, e. g. the production program.
ps Index for n process step
PT var, ps Processing time of variant var of process ps
RS ps Number of identical resources of process ps Acknowledgements
S T var, ps Setup time of variant var of process ps
T A ps Technical availability of process ps This research was made mainly possible through the project “em-
T T ps Customer takt of process ps power” at the University of Bayreuth and the Fraunhofer Society. The
var Index for i product variant project was funded by the Upper Franconia Foundation. The authors
WD ps Available working days of process ps would like to thank the foundation and all participating partners.
WT ps Available working time of process ps
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