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Development of a planning concept for a standardized material supply in the complex production of large volume products with low production units (SySMaG)

(Project duration: January 2017 to Dezember 2018)

Problem Definition

Complex, large-volume products present a variety of challenges for manufacturing companies in mechanical engineering, since the awarding of contracts is often individually prioritized and carried out on call. large-volume products are usually manufactured in individual and small series, which represent the dominant type of production in SMEs.

A high rationalisation potential in the individual and small series production of large volume products is shown by the material supply, whose degree of standardisation is significantly lower compared to the large series production. As a result,the planning and control of the material supply processes is always associated with a high expenditure of time. Although this effort could be reduced by appropriate IT-based planning tools, these are however dependent on a reliable planning database and usually require high investment costs, so that these tools are rarely used in individual and small series production. In order to make use of the advantages of lean production, which is already used in large series production, in individual and small series production of complex large volume products, an innovative concept for the planning ans control of material supply has to be developed.


The goal of the research project SySMaG is to develop a concept for the planning and control of a standardized material supply in the individual and small series production of large volume products.

This concept enables SMEs to select efficient material supply strategies for a heterogeneous product spectrum and to generate dynamic layouts for the material supply. By that the planning and control effort for production logistics is reduced and at the same time idle times due to material bottlenecks are prevented through an optimized material availability and arrangement at the workplace. As a result, non-value-adding assembly activities such as searching and walking times are reduced and throughput times are shortened.

In order to reduce the planning effort and the planning duration, the developed concept is based on a database which, despite the given variability, generates accurate and at the same time robust results. In order to create this database machine learning procedures are used to identify recurring structures in material supply processes. The identified patterns are used to propose adaptable solutions to the planner when (re)planning the material supply and thus reduces the planning effort and planning duration.

In order to optimize the control of the material supply and to ensure a close interlocking with the assembly, the planning of the material supply has to be excecuted dynamically depending on the respective production progress.

To ensure an efficient use of the planning concept in SMEs, the concept is transferred into an IT demonstrator that supports the planner in planning and controlling the material provision process.


The research project is divided into five successive work packages (requirement analysis and definition, development of the planning concept, validation, operationalisation, documentation and transfer of results). The starting point is a requirement analysis to define the requirements for the material supply in the individual and small series production of large volume products.

In the second work package, established material supply concepts in both individual and small series as well as in large series production are examined and evaluated with regard to their suitability for meeting the defined requirements. On this basis the new planning concept is developed.

In addition to the adaptation and further development of suitable material supply methods for the generation of dynamic layout adaptions and for the derivation of standardised workcontent descriptions, a control concept for the synchronisation of the assembly and the production logistics will be developed. The developed concept will then be transferred into an IT demonstrator.





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promotional note

The IGF project (19185 N/1) of the research association for transport business management and logistics e.V. - GVB, Wiesenweg 2, 93352 Rohr is funded by the AiF within the framework of the programme for the promotion of joint industrial research and development (IGF) of the Federal Ministry of Economics and Technology on the basis of a resolution of the German Bundestag.