1st Edition
Process Oriented Analysis Design and Optimization of Industrial Production Systems
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.
Process Oriented Analysis
Introduction
Concept of POA
Static Analysis
Dynamic Analysis
Setup of a Production Analysis
Projects Using POA Models
Organization of the Book
Delimitation of Process Oriented Analysis
Introduction
Upper and Lower CASE
Structured Analysis
Unified Modeling Language (UML)
Computer Support
STATIC ANALYSIS TOOLS
Flow Diagram
Introduction
Flow Diagram: Why?
Flow Diagram Elements
System Boundary
System Structuring in the Hierarchy
Element Specification and Data Dictionary
Setup of a Model and Recommendations
Application Examples: Gas Station
Apply Your Knowledge
Value Flow Diagram
Introduction
Value Flow Diagram: Why?
VFD Elements
Flow Types and Flow Categories
Calculation of the Value
Element Specification and Calculation
Special Examples
Application Example: Gas Station
Apply Your Knowledge
Resource Flow Diagram
Introduction
Resource Flow Diagram: Why?
RFD Elements
Flow Types and Flow Categories
Calculation in the Flow and Process Specification
Mass Analysis in the RFD
Energy Analysis in the RFD
Exergy Analysis
Embodied Energy Analysis
Application Example: Gas Station
Apply Your Knowledge
DYNAMIC ANALYSIS TOOLS
State Chart
Introduction
State Chart: Why?
State Chart Elements
Model Structure
From Flow Diagram to State Chart
Recommendation and Guidelines
Application Example: Gas Station
Apply Your Knowledge
Simulation Model
Introduction
Simulation Model: Why?
From Flow Diagram to Code
Application of Commercial Simulation Packages
Application Example: Gas Station
Apply Your Knowledge
Real-Time Control
Introduction
POA for Real-Time Control: Why?
Machinery States of Manufacturing Processes
System View in the State Domain
Program Design and Coding
Programmable Logic Control of a Fan Heater
Application Example: Gas Pump
Apply Your Knowledge
CASE STUDIES
System Analysis of a Service Enterprise
Getting to know the Operation of a Bar
Setting up the Model
Evaluation Report and Benefits of the Method
Economical Analysis of a Weaving Mill with Integrated Finishing
Model of a Production Plant
Company and Product
Procedure for Setting up a Model
Value Flow Diagram of WeaveFine
Evaluation Report and Benefits of the Method
Exergy Analysis of an Industrial Bakery
Energy Analysis of the Croissant Line
Resource Flow Diagrams of the Croissant Line
Exergy Balance of the Baking Process
Benefits of the Method
System Control for the Demagnetizing of TV Display Tubes
Demagnetizing of TV Display Tubes
New Conception of a Demagnetizing Process Line
System Architecture of the New Production Line
Process Control for Degauss Production Line
Benefits of the Method
Operational Concept for an Automated Plant
New Production Setup
What is Texturizing?
Dynamic Model of the Texturizing Plant
Simulation Program for the Texturizing Plant
Results and Benefits of the Model
Reengineering of a Cable Car
Cable Car System
Reengineering of a Transport Process
Flow Diagrams and State Charts
Transport Simulation
Conclusions and Benefit of the Model
Appendix
Abbreviations
Glossary
Bibliography
Index
Biography
Simone E. Creux, Urs B. Meyer, Andrea K. Weber Marin
