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.

I Introduction to the Process Oriented Analysis	p. 1
I1 Process Oriented Analysis	p. 3
1.1 Introduction	p. 4
1.2 Concept of POA	p. 6
1.3 Static Analysis	p. 8
1.3.1 System Specification	p. 8
1.3.2 Economical Analysis	p. 9
1.3.3 Ecological Analysis	p. 10
1.4 Dynamic Analysis	p. 11
1.4.1 System Behavior	p. 11
1.4.2 Process Simulation	p. 12
1.4.3 Machine and Process Control	p. 13
1.5 Setup of a Production Analysis	p. 14
1.5.1 The Real World in a Model	p. 14
1.5.2 Model Definitions	p. 15
1.5.3 Capture a System	p. 16
1.5.4 Procedure of Setting Up a Model	p. 16
1.6 Projects Using POA Models	p. 18
1.7 Organization of the Book	p. 20
I2 Delimitation of Process Oriented Analysis	p. 23
2.1 Introduction	p. 24
2.2 Upper and Lower Case	p. 25
2.3 Structured Analysis	p. 26
2.3.1 Method Description	p. 26
2.3.2 Delimitation POA to SA	p. 27
2.4 Unified Modeling Language UML	p. 29
2.4.1 Method Description	p. 29
2.4.2 Delimitation POA to UML	p. 30
2.5 Computer Support	p. 32
2.5.1 Case Tools	p. 32
2.5.2 Programming	p. 34
S Static Analysis Tools	p. 35
S1 Flow Diagram	p. 37
1.1 Introduction	p. 38
1.2 Flow Diagram: Why?	p. 39
1.2.1 Purpose	p. 39
1.2.2 Application	p. 40
1.2.3 Delimitation	p. 41
1.3 Flow Diagram Elements	p. 44
1.3.1 Diagram	p. 44
1.3.2 Process	p. 45
1.3.3 Flow	p. 47
1.3.4 Classification of Flows	p. 52
1.3.5 Rules for Processes and Flows	p. 53
1.4 System Boundary	p. 55
1.4.1 External Entity	p. 55
1.4.2 Context Diagram	p. 56
1.4.3 Rules for External Entity and Context Diagram	p. 57
1.5 System Structuring in the Hierarchy	p. 59
1.5.1 System Structuring	p. 59
1.5.2 Numbering of Processes and Diagrams	p. 59
1.5.3 Balancing Parent Process and Child Diagram	p. 60
1.5.4 Principle of Structuring	p. 61
1.5.5 Hierarchy of Flows by Split and Merge	p. 63
1.5.6 Rules for Flow Connections and Hierarchical Structure	p. 66
1.6 Element Specification and Data Dictionary	p. 68
1.6.1 Element Specification	p. 68
1.6.2 Data Dictionary	p. 70
1.7 Setup of a Model and Recommendations	p. 73
1.7.1 Components of a Model	p. 73
1.7.2 Modeling by Hand or Case Tool	p. 74
1.7.3 Recommendations and Guidelines for Expedient Procedure	p. 75
1.7.4 Recommendations and Guidelines for Easy Legible Diagrams	p. 76
1.7.5 Recommendations for System Optimizations	p. 78
1.8 Application Example: Gas Station	p. 81
1.9 Apply Your Knowledge	p. 91
S2 Value Flow Diagram	p. 97
2.1 Introduction	p. 98
2.2 Value Flow Diagram: Why?	p. 99
2.2.1 Purpose	p. 99
2.2.2 Application	p. 100
2.2.3 Delimitation	p. 101
2.2.4 Definitions	p. 102
2.3 VFD Elements	p. 106
2.3.1 From Flow Diagram to VFD	p. 106
2.3.2 Process	p. 106
2.3.3 External Entity	p. 106
2.3.4 Value Flow	p. 106
2.4 Flow Types and Flow Categories	p. 110
2.4.1 Classification of Flows	p. 110
2.4.2 Flow Category: Resource and Information Flow	p. 114
2.4.3 Flow Category: Product Flow	p. 114
2.4.4 Flow Category: Fictitious Value Flow	p. 117
2.4.5 Flow Category: Money Flow	p. 120
2.5 Calculation of the Value	p. 123
2.5.1 Procedure of Value Calculation	p. 123
2.5.2 Principles of the Value Calculation	p. 123
2.5.3 Value Calculation in the Hierarchy	p. 124
2.5.4 Flow Equation	p. 127
2.5.5 Process Balance	p. 130
2.6 Element Specification and Calculation	p. 132
2.6.1 Declaration of Parameters	p. 132
2.6.2 Flow Specification	p. 133
2.6.3 Process Specification	p. 133
2.6.4 Calculation Based on Equations with Parameters	p. 136
2.7 Special Examples	p. 141
2.7.1 Exchange of Value with Outside World	p. 141
2.7.2 Example of Waste Calculation in a Company	p. 142
2.7.3 Notice of Profit and Loss	p. 144
2.7.4 Investment Analysis	p. 146
2.7.5 Intangible Assets: Labels	p. 148
2.8 Application Example: Gas Station	p. 149
2.9 Apply Your Knowledge	p. 159
S3 Resource Flow Diagram	p. 165
3.1 Introduction	p. 166
3.2 Resource Flow Diagram: Why?	p. 167
3.2.1 Purpose	p. 167
3.2.2 Application	p. 167
3.2.3 Delimitation	p. 168
3.2.4 Definitions	p. 170
3.2.5 Concept of Energy and Exergy	p. 173
3.3 RFD Elements	p. 175
3.3.1 From Flow Diagram to RFD	p. 175
3.3.2 Process	p. 176
3.3.3 Resource Flow	p. 176
3.3.4 External Entity	p. 177
3.4 Flow Types and Flow Categories	p. 178
3.4.1 Flow Classification	p. 178
3.4.2 Flow Category	p. 178
3.4.3 Flow Type	p. 179
3.5 Calculation in the Flow and Process Specification	p. 181
3.5.1 Calculation Procedure	p. 181
3.5.2 Parameter Declaration and Assessment	p. 182
3.5.3 Flow Specification in General	p. 183
3.5.4 Process Specification in General	p. 184
3.6 Mass Analysis in the RFD	p. 186
3.6.1 Mass Balance	p. 186
3.6.2 General Flow Calculation	p. 188
3.7 Energy Analysis in the RFD	p. 193
3.7.1 Total Energy of Resource Flows	p. 193
3.7.2 Energy Balance	p. 195
3.7.3 Process Value: Energetic Efficiency	p. 197
3.8 Exergy Analysis	p. 199
3.8.1 Exergy of Resource Flows	p. 199
3.8.2 Exergy Balance	p. 200
3.8.3 Example: Exergy Analysis of a Draw Winding Machine	p. 201
3.8.4 Process Value: Exergetic Efficiency	p. 206
3.9 Embodied Energy Analysis	p. 207
3.9.1 Embodied Energy Calculation	p. 207
3.9.2 Process Value: Embodied Energy Added	p. 208
3.9.3 Example: Embodied Energy Calculation of a Textile Yarn	p. 210
3.10 Application Example: Gas Station	p. 213
3.11 Apply Your Knowledge	p. 219
D Dynamic Analysis Tools	p. 225
D1 State Chart	p. 227
1.1 Introduction	p. 228
1.2 State Chart: Why?	p. 229
1.2.1 Purpose	p. 229
1.2.2 Application	p. 229
1.2.3 Delimitation	p. 231
1.3 State Chart Elements	p. 234
1.3.1 Diagram	p. 234
1.3.2 State	p. 234
1.3.3 Transition	p. 235
1.3.4 Rules and Examples for State Charts	p. 240
1.4 Model Structure	p. 244
1.4.1 State Structuring in the Hierarchy	p. 244
1.4.2 Element Specification	p. 248
1.4.3 Data Dictionary	p. 250
1.5 From Flow Diagram to State Chart	p. 253
1.5.1 Hierarchy of Flow Diagram and State Chart	p. 253
1.5.2 Transition from Flow Diagram to State Chart	p. 255
1.5.3 When to Begin with the State Chart in the Hierarchy	p. 258
1.6 Recommendation and Guidelines	p. 260
1.6.1 Recommendation for State Charts	p. 260
1.6.2 Bottom-Up Approach	p. 262
1.6.3 Components of the Model	p. 264
1.7 Application Example: Gas Station	p. 266
1.8 Apply Your Knowledge	p. 271
D2 Simulation Model	p. 277
2.1 Introduction	p. 278
2.2 Simulation Model: Why?	p. 279
2.2.1 Purpose	p. 279
2.2.2 Application	p. 279
2.2.3 Delimitation	p. 281
2.2.4 Definitions	p. 282
2.3 From Flow Diagram to Code	p. 285
2.3.1 Simulation Theory	p. 285
2.3.2 Step-by-Step Procedure	p. 286
2.3.3 Step 1: Purpose and Goal of System and System Boundaries	p. 287
2.3.4 Step 2: Specify System by the Flow Diagram	p. 287
2.3.5 Step 3: Specify Behavior of Processes in Time	p. 289
2.3.6 Step 4: Program Requirements and User Interface	p. 292
2.3.7 Step 5: Write each Program Module in Code	p. 295
2.3.8 Step 6: Code and Setup of the Simulation Model	p. 303
2.3.9 Step 7: Check and Evaluate System Behavior	p. 305
2.4 Application of Commercial Simulation Packages	p. 307
2.4.1 Connection POA and Commercial Simulation Packages	p. 307
2.4.2 Evaluation of Commercial Simulation Packages	p. 308
2.4.3 Example with Simulation Package: Gas Station	p. 310
2.5 Application Example: Gas Station	p. 314
2.5.1 Static Model	p. 314
2.5.2 Dynamic Model	p. 315
2.5.3 User Interface	p. 317
2.5.4 Coding of the Simulation Model	p. 318
2.6 Apply Your Knowledge	p. 324
D3 Real-Time Control	p. 329
3.1 Introduction	p. 330
3.2 POA for Real-Time Control: Why?	p. 331
3.2.1 Purpose	p. 331
3.2.2 Application	p. 332
3.2.3 Delimitation	p. 333
3.2.4 Definitions	p. 334
3.2.5 History of Manufacturing Automation	p. 335
3.3 Machinery States of Manufacturing Processes	p. 339
3.3.1 Operating and Non-Operating States	p. 339
3.3.2 Monitoring of System States	p. 341
3.3.3 Failure Handling	p. 344
3.4 System View in the State Domain	p. 346
3.4.1 Purpose of the State Domain	p. 346
3.4.2 System with Discrete Parameters	p. 347
3.4.3 System with Continuous and Discrete Parameters	p. 349
3.4.4 System with Continuous Parameters	p. 352
3.4.5 Consideration for Model Hierarchy and State Domain	p. 354
3.4.6 Rules for State Domain, State Map, and System States	p. 358
3.5 Program Design and Coding	p. 359
3.5.1 Step-by-Step Procedure for Real-Time Coding	p. 359
3.5.2 System Analysis for Real-Time Control	p. 361
3.5.3 Program Design and Test Simulation	p. 368
3.5.4 Implementation of Real-Time Control	p. 374
3.6 Programmable Logic Control of a Fan Heater	p. 375
3.6.1 Structure of the System	p. 375
3.6.2 System Behavior	p. 376
3.6.3 Risk Analysis	p. 378
3.6.4 Programming Languages for PLC	p. 379
3.7 Application Example: Gas Pump	p. 381
3.7.1 Flow Diagram and Specifications	p. 381
3.7.2 State Charts	p. 383
3.7.3 User Interface and Program Code	p. 384
3.8 Apply Your Knowledge	p. 387
C Case Studies	p. 395
C1 System Analysis of a Service Enterprise	p. 397
1.1 Getting to Know the Operation of a Bar	p. 398
1.2 Setting up the Model	p. 399
1.2.1 Specify the Investigated System	p. 399
1.2.2 Detailing of the Diagrams	p. 402
1.3 Evaluation Report and Benefits of the Method	p. 407
C2 Economical Analysis of a Weaving Mill with Integrated Finishing	p. 409
2.1 Model of a Production Plant	p. 410
2.2 Company and Product	p. 410
2.3 Procedure for Setting up a Model	p. 412
2.4 Value Flow Diagram of WeaveFine	p. 416
2.4.1 Context Diagram	p. 416
2.4.2 VFD Level 1: "Produce Fabric"	p. 417
2.4.3 VFD Lower Levels	p. 424
2.4.4 VFD "Finish + Schedule Article"	p. 427
2.4.5 Fictitious Value Flow to Pass on Costs	p. 428
2.5 Evaluation Report and Benefits of the Method	p. 430
C3 Exergy Analysis of an Industrial Bakery	p. 433
3.1 Energy Analysis of the Croissant Line	p. 434
3.2 Resource Flow Diagrams of the Croissant Line	p. 435
3.2.1 Context Diagram	p. 435
3.2.2 RFD Production Level	p. 436
3.2.3 Mass Calculation of Product Flows	p. 438
3.2.4 Energy Calculation of Resource Flows	p. 440
3.2.5 RFD Second Level of Detail and Production Layout	p. 440
3.3 Exergy Balance of the Baking Process	p. 444
3.3.1 Purpose of the Exergy Balance	p. 444
3.3.2 Exergy Calculation of Material Flows	p. 445
3.3.3 Exergy Calculation of Energy Flows	p. 447
3.3.4 Exergetic Efficiency Calculation	p. 448
3.4 Benefits of the Method	p. 448
C4 System Control for the Demagnetizing of TV Display Tubes	p. 451
4.1 Demagnetizing of TV Display Tubes	p. 452
4.2 New Conception of a Demagnetizing Process Line	p. 453
4.3 System Architecture of the New Production Line	p. 455
4.4 Process Control for Degauss Production Line	p. 458
4.5 Benefits of the Method	p. 461
C5 Operational Concept for an Automated Plant	p. 463
5.1 New Production Setup	p. 464
5.2 What is Texturizing?	p. 465
5.2.1 Set System Boundaries	p. 465
5.2.2 Specify System and its Structure by Flow Diagrams	p. 466
5.3 Dynamic Model of the Texturizing Plant	p. 467
5.3.1 Specify Behavior of Processes in Time	p. 467
5.3.2 State Specification and State List	p. 468
5.4 Simulation Program for the Texturizing Plant	p. 469
5.4.1 Specify Requirements of Program and Design User Interface	p. 469
5.4.2 Evaluations Required of Simulation	p. 470
5.4.3 Parameters	p. 470
5.4.4 Options for Machine Design	p. 472
5.4.5 User Interface	p. 472
5.4.6 Write each Module in Program Code	p. 475
5.4.7 Evaluation	p. 476
5.4.8 Code Example	p. 479
5.5 Results and Benefits of the Method	p. 480
5.5.1 Results of the Texturizing Simulation	p. 480
5.5.2 Benefits of the Method	p. 481
C6 Reengineering of a Cable Car	p. 483
6.1 Cable Car System	p. 484
6.2 Reengineering of a Transport Process	p. 485
6.3 Flow Diagrams and State Charts	p. 486
6.3.1 Flow Diagrams of the System	p. 486
6.3.2 State Chart of the Cable Car Drive	p. 487
6.3.3 System Hierarchy	p. 490
6.4 Transport Simulation	p. 491
6.4.1 Remote Control	p. 491
6.4.2 User Interface	p. 491
6.4.3 Program Code	p. 493
6.5 Conclusions and Benefits of the Method	p. 495
Appendix	p. 497
A.1 Abbreviations	p. 497
A.2 Glossary	p. 499
A.3 Bibliography	p. 501
Index	p. 503

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