HyFlowJobShop - Hybrid, flow-oriented assembly organisation

The flow principle has been used successfully as an organisational form in assembly, especially in scientific management, since the beginning of the 20th century. It is primarily used to operate mass production with high quantities efficiently. However, the market for single items has changed into a buyer's market. Supply chains are being redesigned due to tough international competition, as the globalised demand for customised products at low prices is constantly increasing. As a result, the increasing number of variants with low contribution margins poses considerable challenges for the current assembly systems of manufacturing companies. Assembly lines that could previously be operated economically for homogenised standard products must now be able to map very different work content of the various product variants. The economic operation of these assembly lines is made even more difficult due to the shortening of product life cycles, as the decreasing amortisation period and high acquisition costs of line assembly systems make it difficult to achieve profitability for a broad production program. Although numerous efforts have been made to further optimise assembly lines in terms of efficiency and flexibility with an increasing number of product variants, this still represents a major challenge for the operation and planning of assembly lines.

The aim of the research project is to investigate hybrid organisational forms that combine flow and workshop principles to enable optimal use of the advantages of both organisational forms. To achieve this, the interdependencies within the assembly configuration will be analysed quantitatively. This quantitative analysis will ensure that further general correlations can be applied to a specific scenario so that a recommendation for action can be derived for the specific design of a hybrid organisational form in assembly. This will enable a target-oriented positioning in the area of conflict between the requirements of product variant flexibility and the achievement of production logistics targets.

First, requirements for the configuration of organisational forms in assembly and factors influencing the achievement of logistical goals are identified. To enable the investigation of generally valid interdependencies, a system for the configuration of hybrid organisational forms as a combination of the flow and workshop principles is developed. The system is then implemented in an application-related production scenario. After the identification of relevant control variables, a simulation study is conducted with a simulation model for the respective configuration of the hybrid organisational form in the production scenario. This is followed by a quantitative analysis of selected performance variables as a function of the chosen control variables. Due to the inductive approach, general statements about the configuration of hybrid organisational forms can be derived as mathematical relationships. The scientific findings will be made usable in a process model for transfer into industrial practice.

Funded by the German Research Foundation (Deutsche Forschungsgemeinschaft (DFG)) – 471726131 as research project „Hybrid, flow-oriented assembly organisation“ (HyFlowJobShop).

The following companies are involved in the research project as associated project partners:

• Miele & Cie. KG
• Sennheiser electronic SE & Co.KG
• Volkswagen Commercial Vehicles