ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Mensgerichte productiesystemen: de operator als kenniswerker
Prof.dr.ir. Hendrik Van Landeghem Industrial Systems Engineering and Product Design Universiteit Gent 1
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Inhoud ■ even kennismaken ■ uitdagingen voor de Europese industrie ■ de operator als kenniswerker ■ 3P integraal ontwerpen
© R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Industrial Systems Engineering & Product Design Universiteit Gent ■
IM, Dept. of Industrial Management, UGent Campus Ardoyen ✦ Research into operational systems, holistic design of manufacturing and logistics systems, operations research models to optimize in-plant logistics, supply chain inventory, technology to develop flexible and adaptable workplaces, operations-oriented diagnostic systems to reduce learning curves and speed up continuous improvement methods in industrial companies, … ✦ Center of Excellence for Lean Implementation: Lean for SME’s, Lean Management System, Lean planning systems
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© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
ISyEPD (vervolg) ■
XiaK, Center for Industrial Automation, UGent, Campus Kortrijk ✦ Research into manufacturing and logistics system design (layout, human-related workplace design), use of RFID technology for automatic position capturing of humans, tools, handling equipment and products, experimental setup (see infrastructure) for video capturing of human behaviour within flexible and adaptable workplace designs (incl. Border of Line technology such as pick-to-light, pick-to-voice, ….)
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IDC, Industrial Design Center, UGent, Campus Kortrijk ✦ Research into the effectiveness of human/machine interface design, product/process integrated design method development, including the use of fast prototyping. ✦ Experimental setup to capture human behaviour in technological settings (such as workplaces).
© R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
De realiteit van vandaag én morgen ■
Concurrentieel produceren in West-Europa ✦ de “moeilijke” zaken beter doen Klant-specifieke complexe ✦ aan dezelfde prijs producten in zeer kleine reeksen ✦ aan hoge kwaliteit, snel geleverd ✦ en voortdurend inspelend op nieuwe opportuniteiten
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Kost van arbeid is hoog en blijft hoog ✦ kostprijs van ons sociaal model ✦ ondersteunt de sterke markt (“gouden banaan”) ● “Future factory workers are therefore key resources for industrial competitiveness as well as important consumers.” Bron : Factory of the Future 2020 Roadmap, EU.
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Marginaal effect van bijkomende stand-alone automatisering neemt af, maar reduceert wel meer en meer de flexibiliteit 5
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Uitdaging 1: Dringende nood aan een productiviteitssprong om de loonkloof met Europa te dichten Het is officieel: 33%
we zijn de duurste in Europa
16%
Loonkost per uur 2014
© R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Uitdaging 2: Hoe richten we onze fabrieken in voor een verouderende werknemersgroep zonder in te boeten aan productiviteit?
Fysieke belasting
Cognitieve belasting 7
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
De Europese agenda Factory of the Future 2020 ■ ■ ■
■
Realising reconfigurable, adaptive and evolving factories capable of small scale production Increase human achievements in future European manufacturing systems Increasing the competitiveness through the design of a new product requires the development of a company strategy where product and process innovation is seen as a permanent, widely distributed, multi-level, social-oriented and user-centred activity New approaches to skill and competence development, as well as skill and knowledge management Bron : Factory of the Future 2020 Roadmap, EU.
© R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Kennisgedreven jobs op alle niveaus
Materiaalverbruik < 50%
Producten en diensten met een toegevoegde waarde x 2
Fabriek van de Toekomst
Globale markt
Time to market 2 x sneller Energieverbruik < 50% World class productiesystemen flexibiliteit x2 Bron: EU en Sirris Made Different © R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Kennisgedreven jobs op alle niveaus
Materiaalverbruik < 50%
Producten en diensten met een toegevoegde waarde x 2
Fabriek van de Toekomst
Globale markt
Time to market 2 x sneller Energieverbruik < 50% World class productiesystemen flexibiliteit x2 Bron: EU en Sirris Made Different © R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Time to Market is een Key Performance Indicator Time to market
• Krachtige ontwerpsystemen • Digital Mockup
Design
Production engineering
HQ
HQ/Factory
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Time to Market is een Key Performance Indicator Time to market
Volautomatische productiesystemen
Design
Production engineering
HQ © R. Van Landeghem, 2015.
HQ/Factory
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Na de marktintroductie begint de jacht op efficiëntie Time to market
Time to profit
Price
Design
Production engineering
HQ
Lean Continuous Improvement
HQ/Factory
Factory
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Focus 1: sneller leren Time to market
Reduce time to profit
• • • •
PDCA op de werkvloer Kortcyclische problem solving Operator in de informatieloop Continuous monitoring processes
Price
Design HQ
Production engineering HQ/Factory
© R. Van Landeghem, 2015.
Price
Lean Continuous Improvement Factory
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
De operator als kenniswerker ■ Informatie NAAR de operator ✦ werkinstructies voor varianten ✦ veiligheids- en kwaliteitsboodschappen ✦ ergonomische belasting ✦ ogenblikkelijke efficiëntie en variaties ■
Informatie VAN de operator ✦ stressniveau en biometrische parameters ✦ on the fly instructies filmen voor specifieke situaties ✦ probleemdetectie en instructies voor acties ✦ verbeteringstriggers 15
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Real time monitoring van operator bewegingen
© R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Smart Shopfloor systemen observeren, analyseren en geven adviezen aan de operator
Spaghetti Diagram Smooth data (Moving Average) 580
560
540
Cycle&time&analysis&
Max/Min Ratios
© R. Van Landeghem, 2015.
520
43,5 7,9 57,42 27,05
sec sec % %
y
Average C/T Standard Deviation
500
480
460
440
420 160
170
180
190 x
200
210
220
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Draagbare interfaces als enablers
Hands free ■ Geen hinder bij werken ■ Draadloze communicatie ■ Co-design met operatoren voor aanvaarding ■
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Rules-Skill-Knowledge model van Rasmussen (1983) modelleert informatieverwerking door mens Gebaseerd op KENNIS (Knowledge)
Ervaring
Improvisatie in onbekende situaties Geen routines of regels beschikbaar om de situatie aan te pakken
Gebaseerd op REGELS (Rules) Voorbereide sequenties van taken geactiveerd wanneer de aangepaste regel wordt toegepast: ALS het symptoom=X DAN het probleem=Y ALS het probleem=Y Dan doe Z
Gebaseerd op VAARDIGHEDEN (Skills) Automatische routines die weinig bewuste aandacht vergen
BEWUST
Werk instructies
Training ONBEWUST 19
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Augmented reality voorbeeld in order picking
© R. Van Landeghem, 2015.
Bron: KNAPP, Oostenrijk.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Een voorbeeld: Augmented reality bij BMW
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© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Collaboratieve robots delen werkplek met de operator en verlagen de fysieke belasting van (oudere) werknemers
“As automation takes the next layer of jobs at the current bottom, we humans are asked to do more and more complex stuff, higher up the value hierarchy.” (J. Stogdil, 2015) © R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Voorbeeld cobot voor assemblage
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© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Focus 2: 3P design – Product/Proces/werkPlek Time to market =
Time to profit
Reduce time to profit • • • • • • Price
Design Short cycle Lean Production engineering
© R. Van Landeghem, 2015.
Virtual reality Virtual commissioning Co-design processes met operator Design for Manufacturing Collaborative robots Adaptive automation Price
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Veel fabrieken zijn nog gebouwd op 250 jaar oude principes
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© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Voorbeeld: bevoorrading van de Productielijn Stock Point Supermarket
Supply Aisle
Border of Line
Assembly Line
Bevoorrading in BULK rechtstreeks van de leverancier of in KITS via een ompakslag in de Supermarkt? © R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Kostenmodel alloceert onderdelen optimaal over verschillende scenario’s 30.000 $
25.000 $
20.000 $ MATERIAL COSTS 15.000 $
LABOUR COSTS CAPITAL COSTS OPERATING COSTS
10.000 $
5.000 $
0$ BULK FEEDING
KITTING OEM Centralized
KITTING OEM Decentralized
KITTING SUPPLIER
KITTING AT 3PL
pag. 27
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Effect van materiaalkost op Total Landed Cost Total cost (€)
10 8
Bron: V. Limère, H. Van Landeghem, To Kit or not to Kit, 2014.
6 4 2 0 0
5
10
15
20
25
Warehouse CLOSE to line
Price (€) BULK FEEDING
KITTING OEM
Total cost (€)
10 8 6 4 2 0 0
5
10
15
20
25
Price (€) BULK FEEDING
© R. Van Landeghem, 2015.
KITTING OEM
pag. 28
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Voorbeeld: ontwerp vorkliftvrije fabriek ■ Keuze alternatief transportsysteem ✦ tuggers versus overhead conveyors
Allocatie onderdelen aan kits of bulk ■ Begroten parameters zoals buffers, aantal transportmiddelen, ... ■
✦ is het concept haalbaar? ✦ wat is de downside risk (onderbrekingen productielijn)? ✦ wat gaat het kosten? ■
Project verdient zichzelf terug op basis van efficiënter gebruik van de lijnoperatoren ✦ typische showstopper: 2 vice-presidents betrokken partij 29
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Enabler: Plant Simulation factory logistics model
Scenario)MOD_A.2) Max&of&Diff_Msg_Buf&
2&Takt&Times:&20m06s& 21:21&
15:07&
16:24&
11:59& 08:16&
100&
© R. Van Landeghem, 2015.
90&
80& #&EMS&carriers&
75&
70&
30
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Technologie om te verbeteren 1.
Verminder fysieke belasting ✦ Collaborative robots, exoskeletons, adaptieve, contextafhankelijke automatisering van de werkplek
2.
Verminder cognitieve belasting ✦ Augmented reality real-time informatie-uitwisseling met de operator
3.
Sneller leren door de hele organisatie ✦ Integratie werkvloer met ondersteunende processen (turbocharging continuous improvement)
4.
Integraal ontwerp van product, proces en werkplek ✦ Virtual Reality prototyping van de processen op de werkplekDigital Mockup 31
© R. Van Landeghem, 2015.
ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Verhoog de effectiviteit van operatoren ■ door het combineren van de sterke punten van de mens (creativiteit, probleemoplossend vermogen, dexteriteit) met de snel toenemende sterktes en betaalbaarheid van machine/robot systemen (precisie, repeteerbaarheid, manipulatie van zware onderdelen, toenemende bewustzijn van de omgeving, snelle manipulaties) ■ en het real-time inschakelen van de operator in de informatie-loop op alomtegenwoordige en nietindringende manier
© R. Van Landeghem, 2015.
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ISyE&PD Faculty of Engineering and Architecture
Industrial Systems Engineering and Product Design
Dank u voor uw aandacht!
[email protected]
© R. Van Landeghem, 2015.
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