Process Oriented Analysis: Design and Optimization of Industrial Production Systems

by Meyer; Urs B.

• ISBN13: 9780849374944
• ISBN10: 0849374944
• Format: Hardcover
• Copyright: 2006-09-18
• Publisher: CRC Press

Summary

In modern manufacturing, it is not simply the equipment that is increasingly complex but rather the entire business system in which a company operates. Convoluted supply chains, complicated resource flows, advanced information systems: all must be taken into account when designing or reengineering a manufacturing system. Introducing a powerful yet easy-to-follow method, Process Oriented Analysis: Design and Optimization of Industrial Production Systems offers clear and practical guidance on applying this proven analytical technique to any type of manufacturing operation.Linking abstract theoretical concepts to real-world implementation, this book outlines the principles of Process Oriented Analysis (POA) and demonstrates the application of these concepts using actual case studies. The authors first present the diagrams and analytical tools used in POA to represent both the static structure and dynamic behavior of the system. They then demonstrate how to build a simulation model by translating the diagram components into usable source code. Software for generating these types of diagrams is available for download from the Internet, along with a thorough tutorial that includes questions and interactive case studies.Taking a consistent approach that anyone in the organization can use and understand, Process Oriented Analysis is the perfect resource for planning, designing, debugging, and optimizing modern production systems.

Table of Contents

I INTRODUCTION TO THE PROCESS ORIENTED ANALYSIS	1	(34)
I1 PROCESS ORIENTED ANALYSIS	3	(20)
1.1 Introduction	4	(2)
1.2 Concept of POA	6	(2)
1.3 Static Analysis	8	(3)
1.3.1 System Specification	8	(1)
1.3.2 Economical Analysis	9	(1)
1.3.3 Ecological Analysis	10	(1)
1.4 Dynamic Analysis	11	(3)
1.4.1 System Behavior	11	(1)
1.4.2 Process Simulation	12	(1)
1.4.3 Machine and Process Control	13	(1)
1.5 Setup of a Production Analysis	14	(4)
1.5.1 The Real World in a Model	14	(1)
1.5.2 Model Definitions	15	(1)
1.5.3 Capture a System	16	(1)
1.5.4 Procedure of Setting Up a Model	16	(2)
1.6 Projects Using POA Models	18	(2)
1.7 Organization of the Book	20	(3)
I2DELIMITATION OF PROCESS ORIENTED ANALYSIS	23	(12)
2.1 Introduction	24	(1)
2.2 Upper and Lower CASE	25	(1)
2.3 Structured Analysis	26	(3)
2.3.1 Method Description	26	(1)
2.3.2 Delimitation POA to SA	27	(2)
2.4 Unified Modeling Language UML	29	(3)
2.4.1 Method Description	29	(1)
2.4.2 Delimitation POA to UML	30	(2)
2.5 Computer Support	32	(5)
2.5.1 CASE Tools	32	(2)
2.5.2 Programming	34	(1)
S STATIC ANALYSIS TOOLS	35	(190)
S1 FLOW DIAGRAM	37	(60)
1.1 Introduction	38	(1)
1.2 Flow Diagram: Why?	39	(5)
1.2.1 Purpose	39	(1)
1.2.2 Application	40	(1)
1.2.3 Delimitation	41	(3)
1.3 Flow Diagram Elements	44	(11)
1.3.1 Diagram	44	(1)
1.3.2 Process	45	(2)
1.3.3 Flow	47	(5)
1.3.4 Classification of Flows	52	(1)
1.3.5 Rules for Processes and Flows	53	(2)
1.4 System Boundary	55	(4)
1.4.1 External Entity	55	(1)
1.4.2 Context Diagram	56	(1)
1.4.3 Rules for External Entity and Context Diagram	57	(2)
1.5 System Structuring in the Hierarchy	59	(9)
1.5.1 System Structuring	59	(1)
1.5.2 Numbering of Processes and Diagrams	59	(1)
1.5.3 Balancing Parent Process and Child Diagram	60	(1)
1.5.4 Principle of Structuring	61	(2)
1.5.5 Hierarchy of Flows by Split and Merge	63	(3)
1.5.6 Rules for Flow Connections and Hierarchical Structure	66	(2)
1.6 Element Specification and Data Dictionary	68	(5)
1.6.1 Element Specification	68	(2)
1.6.2 Data Dictionary	70	(3)
1.7 Setup of a Model and Recommendations	73	(8)
1.7.1 Components of a Model	73	(1)
1.7.2 Modeling by Hand or CASE Tool	74	(1)
1.7.3 Recommendations and Guidelines for Expedient Procedure	75	(1)
1.7.4 Recommendations and Guidelines for Easy Legible Diagrams	76	(2)
1.7.5 Recommendations for System Optimizations	78	(3)
1.8 Application Example: Gas Station	81	(10)
1.9 Apply Your Knowledge	91	(6)
S2 VALUE FLOW DIAGRAM	97	(68)
2.1 Introduction	98	(1)
2.2 Value Flow Diagram: Why?	99	(7)
2.2.1 Purpose	99	(1)
2.2.2 Application	100	(1)
2.2.3 Delimitation	101	(1)
2.2.4 Definitions	102	(4)
2.3 VFD Elements	106	(4)
2.3.1 From Flow Diagram to VFD	106	(1)
2.3.2 Process	106	(1)
2.3.3 External Entity	106	(1)
2.3.4 Value Flow	106	(4)
2.4 Flow Types and Flow Categories	110	(13)
2.4.1 Classification of Flows	110	(4)
2.4.2 Flow Category: Resource and Information Flow	114	(1)
2.4.3 Flow Category: Product Flow	114	(3)
2.4.4 Flow Category: Fictitious Value Flow	117	(3)
2.4.5 Flow Category: Money Flow	120	(3)
2.5 Calculation of the Value	123	(9)
2.5.1 Procedure of Value Calculation	123	(1)
2.5.2 Principles of the Value Calculation	123	(1)
2.5.3 Value Calculation in the Hierarchy	124	(3)
2.5.4 Flow Equation	127	(3)
2.5.5 Process Balance	130	(2)
2.6 Element Specification and Calculation	132	(9)
2.6.1 Declaration of Parameters	132	(1)
2.6.2 Flow Specification	133	(1)
2.6.3 Process Specification	133	(3)
2.6.4 Calculation Based on Equations with Parameters	136	(5)
2.7 Special Examples	141	(8)
2.7.1 Exchange of Value with Outside World	141	(1)
2.7.2 Example of Waste Calculation in a Company	142	(2)
2.7.3 Notice of Profit and Loss	144	(2)
2.7.4 Investment Analysis	146	(2)
2.7.5 Intangible Assets: Labels	148	(1)
2.8 Application Example: Gas Station	149	(10)
2.9 Apply Your Knowledge	159	(6)
S3 RESOURCE FLOW DIAGRAM	165	(60)
3.1 Introduction	166	(1)
3.2 Resource Flow Diagram: Why?	167	(8)
3.2.1 Purpose	167	(1)
3.2.2 Application	167	(1)
3.2.3 Delimitation	168	(2)
3.2.4 Definitions	170	(3)
3.2.5 Concept of Energy and Exergy	173	(2)
3.3 RFD Elements	175	(3)
3.3.1 From Flow Diagram to RFD	175	(1)
3.3.2 Process	176	(1)
3.3.3 Resource Flow	176	(1)
3.3.4 External Entity	177	(1)
3.4 Flow Types and Flow Categories	178	(3)
3.4.1 Flow Classification	178	(1)
3.4.2 Flow Category	178	(1)
3.4.3 Flow Type	179	(2)
3.5 Calculation in the Flow and Process Specification	181	(5)
3.5.1 Calculation Procedure	181	(1)
3.5.2 Parameter Declaration and Assessment	182	(1)
3.5.3 Flow Specification in General	183	(1)
3.5.4 Process Specification in General	184	(2)
3.6 Mass Analysis in the RFD	186	(7)
3.6.1 Mass Balance	186	(2)
3.6.2 General Flow Calculation	188	(5)
3.7 Energy Analysis in the RFD	193	(6)
3.7.1 Total Energy of Resource Flows	193	(2)
3.7.2 Energy Balance	195	(2)
3.7.3 Process Value: Energetic Efficiency	197	(2)
3.8 Exergy Analysis	199	(8)
3.8.1 Exergy of Resource Flows	199	(1)
3.8.2 Exergy Balance	200	(1)
3.8.3 Example: Exergy Analysis of a Draw Winding Machine	201	(5)
3.8.4 Process Value: Exergetic Efficiency	206	(1)
3.9 Embodied Energy Analysis	207	(6)
3.9.1 Embodied Energy Calculation	207	(1)
3.9.2 Process Value: Embodied Energy Added	208	(2)
3.9.3 Example: Embodied Energy Calculation of a Textile Yarn	210	(3)
3.10 Application Example: Gas Station	213	(6)
3.11 Apply Your Knowledge	219	(6)
D DYNAMIC ANALYSIS TOOLS	225	(170)
D1 STATE CHART	227	(50)
1.1 Introduction	228	(1)
1.2 State Chart: Why?	229	(5)
1.2.1 Purpose	229	(1)
1.2.2 Application	229	(2)
1.2.3 Delimitation	231	(3)
1.3 State Chart Elements	234	(10)
1.3.1 Diagram	234	(1)
1.3.2 State	234	(1)
1.3.3 Transition	235	(5)
1.3.4 Rules and Examples for State Charts	240	(4)
1.4 Model Structure	244	(9)
1.4.1 State Structuring in the Hierarchy	244	(4)
1.4.2 Element Specification	248	(2)
1.4.3 Data Dictionary	250	(3)
1.5 From Flow Diagram to State Chart	253	(7)
1.5.1 Hierarchy of Flow Diagram and State Chart	253	(2)
1.5.2 Transition from Flow Diagram to State Chart	255	(3)
1.5.3 When to Begin with the State Chart in the Hierarchy	258	(2)
1.6 Recommendation and Guidelines	260	(11)
1.6.1 Recommendation for State Charts	260	(2)
1.6.2 Bottom-Up Approach	262	(2)
1.6.3 Components of the Model	264	(2)
1.7 Application Example: Gas Station	266	(5)
1.8 Apply Your Knowledge	271	(6)
D2 SIMULATION MODEL	277	(52)
2.1 Introduction	278	(1)
2.2 Simulation Model: Why?	279	(6)
2.2.1 Purpose	279	(1)
2.2.2 Application	279	(2)
2.2.3 Delimitation	281	(1)
2.2.4 Definitions	282	(3)
2.3 From Flow Diagram to Code	285	(22)
2.3.1 Simulation Theory	285	(1)
2.3.2 Step-by-Step Procedure	286	(1)
2.3.3 Step 1: Purpose and Goal of System and System Boundaries	287	(1)
2.3.4 Step 2: Specify System by the Flow Diagram	287	(2)
2.3.5 Step 3: Specify Behavior of Processes in Time	289	(3)
2.3.6 Step 4: Program Requirements and User Interface	292	(3)
2.3.7 Step 5: Write each Program Module in Code	295	(8)
2.3.8 Step 6: Code and Setup of the Simulation Model	303	(2)
2.3.9 Step 7: Check and Evaluate System Behavior	305	(2)
2.4 Application of Commercial Simulation Packages	307	(7)
2.4.1 Connection POA and Commercial Simulation Packages	307	(1)
2.4.2 Evaluation of Commercial Simulation Packages	308	(2)
2.4.3 Example with Simulation Package: Gas Station	310	(4)
2.5 Application Example: Gas Station	314	(10)
2.5.1 Static Model	314	(1)
2.5.2 Dynamic Model	315	(2)
2.5.3 User Interface	317	(1)
2.5.4 Coding of the Simulation Model	318	(6)
2.6 Apply Your Knowledge	324	(5)
D3 REAL-TIME CONTROL	329	(66)
3.1 Introduction	330	(1)
3.2 POA for Real-Time Control: Why?	331	(8)
3.2.1 Purpose	331	(1)
3.2.2 Application	332	(1)
3.2.3 Delimitation	333	(1)
3.2.4 Definitions	334	(1)
3.2.5 History of Manufacturing Automation	335	(4)
3.3 Machinery States of Manufacturing Processes	339	(7)
3.3.1 Operating and Non-Operating States	339	(2)
3.3.2 Monitoring of System States	341	(3)
3.3.3 Failure Handling	344	(2)
3.4 System View in the State Domain	346	(13)
3.4.1 Purpose of the State Domain	346	(1)
3.4.2 System with Discrete Parameters	347	(2)
3.4.3 System with Continuous and Discrete Parameters	349	(3)
3.4.4 System with Continuous Parameters	352	(2)
3.4.5 Consideration for Model Hierarchy and State Domain	354	(4)
3.4.6 Rules for State Domain, State Map, and System States	358	(1)
3.5 Program Design and Coding	359	(16)
3.5.1 Step-by-Step Procedure for Real-Time Coding	359	(2)
3.5.2 System Analysis for Real-Time Control	361	(7)
3.5.3 Program Design and Test Simulation	368	(6)
3.5.4 Implementation of Real-Time Control	374	(1)
3.6 Programmable Logic Control of a Fan Heater	375	(6)
3.6.1 Structure of the System	375	(1)
3.6.2 System Behavior	376	(2)
3.6.3 Risk Analysis	378	(1)
3.6.4 Programming Languages for PLC	379	(2)
3.7 Application Example: Gas Pump	381	(6)
3.7.1 Flow Diagram and Specifications	381	(2)
3.7.2 State Charts	383	(1)
3.7.3 User Interface and Program Code	384	(3)
3.8 Apply Your Knowledge	387	(8)
C CASE STUDIES	395	(102)
C1 SYSTEM ANALYSIS OF A SERVICE ENTERPRISE
1.1 Getting to Know the Operation of a Bar	398	(1)
1.2 Setting up the Model	399	(8)
1.2.1 Specify the Investigated System	399	(3)
1.2.2 Detailing of the Diagrams	402	(5)
1.3 Evaluation Report and Benefits of the Method	407	(2)
C2 ECONOMICAL ANALYSIS OF A WEAVING MILL WITH INTEGRATED FINISHING	409	(24)
2.1 Model of a Production Plant	410	(1)
2.2 Company and Product	410	(2)
2.3 Procedure for Setting up a Model	412	(4)
2.4 Value Flow Diagram of WeaveFine	416	(14)
2.4.1 Context Diagram	416	(1)
2.4.2 VFD Level 1: "Produce Fabric"	417	(7)
2.4.3 VFD Lower Levels	424	(3)
2.4.4 VFD "Finish + Schedule Article"	427	(1)
2.4.5 Fictitious Value Flow to Pass on Costs	428	(2)
2.5 Evaluation Report and Benefits of the Method	430	(3)
C3 EXERGY ANALYSIS OF AN INDUSTRIAL BAKERY	433	(18)
3.1 Energy Analysis of the Croissant Line	434	(1)
3.2 Resource Flow Diagrams of the Croissant Line	435	(9)
3.2.1 Context Diagram	435	(1)
3.2.2 RFD Production Level	436	(2)
3.2.3 Mass Calculation of Product Flows	438	(2)
3.2.4 Energy Calculation of Resource Flows	440	(1)
3.2.5 RFD Second Level of Detail and Production Layout	440	(4)
3.3 Exergy Balance of the Baking Process	444	(4)
3.3.1 Purpose of the Exergy Balance	444	(1)
3.3.2 Exergy Calculation of Material Flows	445	(2)
3.3.3 Exergy Calculation of Energy Flows	447	(1)
3.3.4 Exergetic Efficiency Calculation	448	(1)
3.4 Benefits of the Method	448	(3)
C4 SYSTEM CONTROL FOR THE DEMAGNETIZING OF TV DISPLAY TUBES	451	(12)
4.1 Demagnetizing of TV Display Tubes	452	(1)
4.2 New Conception of a Demagnetizing Process Line	453	(2)
4.3 System Architecture of the New Production Line	455	(3)
4.4 Process Control for Degauss Production Line	458	(3)
4.5 Benefits of the Method	461	(2)
C5 OPERATIONAL CONCEPT FOR AN AUTOMATED PLANT	463	(20)
5.1 New Production Setup	464	(1)
5.2 What is Texturizing?	465	(2)
5.2.1 Set System Boundaries	465	(1)
5.2.2 Specify System and its Structure by Flow Diagrams	466	(1)
5.3 Dynamic Model of the Texturizing Plant	467	(2)
5.3.1 Specify Behavior of Processes in Time	467	(1)
5.3.2 State Specification and State List	468	(1)
5.4 Simulation Program for the Texturizing Plant	469	(11)
5.4.1 Specify Requirements of Program and Design User Interface	469	(1)
5.4.2 Evaluations Required of Simulation	470	(1)
5.4.3 Parameters	470	(2)
5.4.4 Options for Machine Design	472	(1)
5.4.5 User Interface	472	(3)
5.4.6 Write each Module in Program Code	475	(1)
5.4.7 Evaluation	476	(3)
5.4.8 Code Example	479	(1)
5.5 Results and Benefits of the Method	480	(3)
5.5.1 Results of the Texturizing Simulation	480	(1)
5.5.2 Benefits of the Method	481	(2)
C6 REENGINEERING OF A CABLE CAR	483	(14)
6.1 Cable Car System	484	(1)
6.2 Reengineering of a Transport Process	485	(1)
6.3 Flow Diagrams and State Charts	486	(5)
6.3.1 Flow Diagrams of the System	486	(1)
6.3.2 State Chart of the Cable Car Drive	487	(3)
6.3.3 System Hierarchy	490	(1)
6.4 Transport Simulation	491	(4)
6.4.1 Remote Control	491	(1)
6.4.2 User Interface	491	(2)
6.4.3 Program Code	493	(2)
6.5 Conclusions and Benefits of the Method	495
APPENDIX
A.1 Abbreviations	497	(2)
A.2 Glossary	499	(2)
A.3 Bibliography	501	(2)
INDEX	503