Skip to main content
SpringerLink
Log in

Cost-benefit analysis for disruption prevention in low-volume assembly

  • Production Management
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

Manufacturing companies face rising pressure due to increased competition. Traditionally, companies have merely concentrated on offering impeccable, cost-efficient products. Today, however, flexibility and on-time delivery are additional requirements to satisfy the customers. At the same time, disruptions in production, especially in low-volume assembly, still frequently occur, leading to economic losses and delayed customer deliveries. The approach proposed in this paper strives for improving the disruption situation in low-volume assemblies. A detailed disruption management methodology has been developed, aiming at realizing an efficient reduction of disruptions, while at the same time considering the specific characteristics of low-volume assembly. The methodology is supported by a catalog of pre-emptive measures. These measures are known to reduce the disruptions’ occurrence or to diminish their consequences. In general, the approach pursues the basic idea to implement particularly those measures, which have the best cost-benefit-ratio. Based on the analysis of the cost-benefit-ratio of each measure, the developed methodology aims at improving the disruption situation in assembly and thus providing a high on-time delivery rate. The usability of the methodology for the low-volume assembly context has been confirmed by assembly experts on the basis of an application of the methodology in an exemplary case study.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Abele E, Meyer T, Näher U, Strube G, Sykes R (2006) Global production: a handbook for strategy and implementation. Springer, Berlin Heidelberg

    Google Scholar 

  2. Womack JP, Jones T, Roos D (1991) The machine that changed the world: the story of lean production. 1st edn. Harper Perennial, New York

    Google Scholar 

  3. Schuh G, Potente T, Jasinski T (2013) Decentralized, Market-Driven coordination mechanism based on the monetary value of in time deliveries. Proceedings of Global Business Research Conference, Kathmandu

  4. Gunasekaran A, Forker L, Kobu B (2000) Improving operations performance in a small company: a case study. Int J Oper Prod Manag 20:316–336

    Article  Google Scholar 

  5. Petersen T (2005) Organisationsformen der Montage. Shaker, Aachen

    Google Scholar 

  6. Münzberg B, Schmidt M, Beck S, Nyhuis P (2012) Model based logistic monitoring for supply and assembly processes. Prod Eng Res Develop 6:449–458

  7. Whitney D (2004) Mechanical assemblies. Oxford University Press, New York

    Google Scholar 

  8. Cauvin ACA, Ferrarini AFA, Tranvouez, ETE (2009) Disruption management in distributed enterprises: a multi-agent modelling and simulation of cooperative recovery behaviours. Int J Prod Econ 122:429–439

    Article  Google Scholar 

  9. Eversheim W (1992) Störungsmanagement in der Montage. 1st edn. Springer-VDI, Düsseldorf

  10. Kampker A, Burggräf P, Bäumers Y (2014) Economic level of detail for assembly planning. IEEE International Conference on Industrial Engineering and Engineering Management, Selangor Darul Ehsan/Malaysia, pp 516–520

  11. Kampker A, Wagner J, Burggräf P, Bäumers Y (2015) Criticality-focused, pre-emptive disruption management in low-volume assembly. Proceedings of Abstract and Papers of 23rd International Conference on Production Research ICPR23—Operational Excellence towards sustainable development goals (SDG) through Industry 4.0, Manila/Philippines

  12. Burggräf P, Reuter C, Böning C, Wagner J, Schmitz T, Prinzhorn H, Ebertz J (2016) Monetäre Bewertung von Montageplänen—Bewertung von Montageplanalternativen anhand der logistischen Zielgrößen im Störungsfall. Werkstattstechnik online (wt online) 106:236–242

  13. Abumaizar RJ, Svestka JA (1997) Rescheduling job shops under random disruptions. Int J Prod Res 35:2065–2082

    Article  MATH  Google Scholar 

  14. Meyer G, Knüppel K, Schmidt M, Nyhuis P. (2014) Störgrößenmanagement-Systematik. Zeitschrift für wirtschaftlichen Fabrikbetrieb (ZWF) 109:704–707

  15. Meyer G, Brünig B (2014) Competence Development Measures—Employee Development in Times of Demographic Change. Official Conference Proceedings of The Asian Conference on Society, Education & Technology, Osaka

  16. Heil M (1995) Entstörung betrieblicher Abläufe. Gabler, Wiesbaden

    Book  Google Scholar 

  17. Burggräf P (2012) Wertorientierte Fabrikplanung. Apprimus, Aachen

  18. Kampker A, Burggräf P, Bäumers Y (2015) Determination of the Economic Planning Depth for Assembly Process Planning. Int J Soc Behav Educ Econ Bus Indus Eng 9:3619–3624

    Google Scholar 

  19. Bräunig D, Kohstall T (2013) Calculating the international return on prevention for companies: costs and benefits of investments in occupational safety and health. German Social Accident Insurance (DGUV), Berlin

  20. Deutsches Institut für Normung e.V. (1983) DIN66001 Sinnbilder und ihre Anwendung. Beuth, Berlin

    Google Scholar 

  21. Rochow P, Burggräf P, Reuter C, Prinzhorn H, Wagner J, Schmitz T (2015) Identification of alternative assembly sequences for large-scale products. Proceedings of the POMS Conference, Washington

  22. Lehmann F (1992) Störungsmanagement in der Einzel- und Kleinserienmontage. Shaker, Aachen

    Google Scholar 

  23. Dahlgaard J, Kristensen K, Kanji G (2007) Fundamentals of total quality management. Taylor & Francis, London

    Google Scholar 

  24. Carlson C (2012) Effective FMEAs—achieving safe, reliable and economical products and processes using failure mode and effects analysis. Wiley, Hoboken

    Book  Google Scholar 

  25. Kadipasaoglu SN, Sridharan V (1995) Alternative approaches for reducing schedule instability in multistage manufacturing under demand uncertainty. J Oper Manage 13:193–211

    Article  Google Scholar 

  26. Backes-Gellner U, Veen S (2013) Positive effects of ageing and age diversity in innovative companies—large-scale empirical evidence on company productivity. Hum Resour Manag J 23:279–295

  27. Wagner J, Burggräf P, Bäumers Y, Löher C (2015) Störungsrelevante Montageprozesse erkennen—Eine Bewertungsmethodik für die Kleinserie. Zeitschrift für wirtschaftlichen Fabrikbetrieb (ZWF) 110:787–790

  28. Ehrgott M (2012) Vilfredo Pareto and multi-objective optimization. Documenta Mathematica—21st International Symposium on Mathematical Programming, Berlin, pp 447–453

Download references

Author information

Authors and Affiliations

  1. Laboratory for Machine Tools and Production Engineering WZL, RWTH Aachen University, Steinbachstraße 19, 52074, Aachen, Germany

    Peter Burggräf, Johannes Wagner, Katrin Lück & Tobias Adlon

Authors
  1. Peter Burggräf
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Johannes Wagner
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Katrin Lück
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Tobias Adlon
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Johannes Wagner.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Burggräf, P., Wagner, J., Lück, K. et al. Cost-benefit analysis for disruption prevention in low-volume assembly. Prod. Eng. Res. Devel. 11, 331–342 (2017). https://doi.org/10.1007/s11740-017-0735-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-017-0735-6

Keywords

Search

Navigation