Digital Production Planning

Today's production planning faces enormous challenges and is strategically and operationally influenced by short product life cycles, short planning lead times, a high number of variants, increasing cost pressure, fluctuating quantities and last but not least by demographic change and end-to-end digitization. To enable our customers to master these challenges in the future, we bundle our distinctive expertise in production planning with the latest software technology and offer methodical competencies in digital factory, material flow, production and assembly planning as well as in virtual process assurance.

With the know-how of our planning engineers as well as modern technologies and methods, we help companies to increase productivity and ergonomics through virtual production planning and workplace design.

Digital Production Planning

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Services

  • conception, implementation and presentation of digital planning projects
  • training and workshops on digital planning methods
  • piloting of digital planning projects
Main Focus - Digital Factory and Material Flow Planning
  • 3D material flow visualization
  • quantity determination
  • resource and utilization planning
  • determination of requirements for production areas
  • lead time calculation
  • planning and analysis of production costs

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to   the   ema Plant Designer
Main Focus - Digital Workplace and Process Design
  • workplace design
  • definition of behaviour and work process structure
  • 3D simulation
  • ergonomics evaluation and optimization
  • process evaluation via MTM-UAS
  • walkpath analysis and optimization

Link

to the   ema Work Designer

Fields of application and advantages

Conception, planning, 3D simulation, evaluation and optimization of production processes, material flows, manual and semi-automated activities and human-robot collaboration. Significant benefits for more profitability and sustainability already in the concept phase through prospective workplace design, digital process planning and 3D simulation with the ema Software Suite.

Production Planning
Application Area - Production and Material Flow Planning
For the fast and precise planning and evaluation of production processes, we combine the best of the worlds of simulation and value stream. Digital solutions provide reliable and resilient results for the utilization of workstations including bottleneck analysis, manufacturing costs, throughput times and critical paths, required buffer space, as well as production space and material flows. This allows for lean and highly efficient workshop, row, island or flow production.
 
Further advantages:
  • variant planning
  • quantity determination
  • reduction of transport routes and 3D material flow visualization
  • mapping of dynamic production and logistics processes
  • analysis of the overall system
Workplace and Process Design
Application Field - Workplace and process design
Integrated digital planning combines classic factory planning with simulation of human work in production, including time management, cycle time diagrams, waste analysis and value creation determination. In addition to conventional production planning, we use modern 3D technology and valid methodology to support in particular the planning of manufacturing and assembly processes with manual activities.
 
This results in the following advantages:
  • prospective planning, design and optimization of manual and semi-automated activities
  • fast planning of process variants
  • determination of optimal use of personnel and operating resources
  • virtualization of the Continuous Improvement Process
  • generation of results and reports based on recognized industry standards (MTM and EAWS)
Virtual Ergonomics
Application Field - Virtual Ergonomics
Prospective work design is becoming increasingly important due to the effects of demographic change, shorter product lifecycles or an increasing number of variants. We provide support in the conceptual design, validation and development of design variants with the help of digital human models and 3D imaging of planned or to be optimized workplaces and processes. By means of a semi-automatic ergonomics assessment, physical stress factors can be taken into account and work processes can be designed ergonomically already in the planning phase.
 
Further advantages:
  • fulfillment of legal and operational requirements through human-oriented workplace design
  • ensuring the value-adding deployment of personnel for highest quality and productivity
  • reduced absenteeism through ergonomic workstations
  • ergonomic design of machines and systems taking into account different body sizes according to DIN EN 33402-2
Human-robot Collaboration
Application Field - Human-robot Collaboration
A modern production combines the strengths of the human being with the advantages of efficient technologies and organizational structures.    Human-robot collaboration is increasingly being used in production and stands for more efficiency, ergonomics and quality. We support digital planning, 3D simulation and evaluation of such HRC systems and human-machine interactions.
 
The symbiosis of automation, human simulation, time management and industrial safety including automatic collision detection and safety evaluation enables:
  • qualified predictions of economic efficiency in the concept phase
  • optimal process design of MRK stations under practical conditions and under consideration of DIN standards
  • planning with integrated 3D-objects of robots from various manufacturers et. al. ABB, BOSCH, KUKA, Staeubli, UR und Yaskawa
  • early protection against trade associations and works councils
  • reduction of the effort for commissioning
  • virtual commissioning of production plants with robots and human work