Methode zur Reduktion technischer Nebenzeiten in der spanenden Fertigung

Die Effizienz von Fertigungsprozessen kann durch die Reduktion technischer Nebenzeiten deutlich gesteigert werden. Hierzu wird eine Methode vorgestellt, welche die äußerst komplexe Aufgabe der Optimierung des Fertigungsprozesses vereinfachen kann. Die Methode besteht aus Verfahren der Potenzialanalyse und der Optimierung. Diese Verfahren werden anschließend exemplarisch an Fertigungsprozessen der automobilen Großserienfertigung angewandt und die daraus resultierenden Erfolge aufgezeigt.

Economic pressures and the increasing importance of resource efficiency make the streamlining of production processes necessary. In this context, the reduction of non-productive times, i.e. of the part of machine tools' total run time which, contrary to productive times, does not create value, represents an important lever. The percentage of non-productive times of many modern production processes is just below or even above that of productive times. However, streamlining non-productive times is extremely complicated. Computerized Numerical Controls (CNC) are very comprehensive in terms of their usage, specification language and parameter settings. Only very few people possess the specialised knowledge required for streamlining non-productive times. In order to counter this situation, a new method to reduce non-productive times will be covered in this thesis. For this purpose eight different processes to analyse the potential of non-productive times will be presented first. Following on from that, the actual method for reducing non-productive times is introduced. It consists of eight groups organised by topic, each representing a different streamlining process. Three of these groups will be the focus of this thesis. The eight groups will be covered and compared to one another. At the same time specific benefits and disadvantages are also detailed. However, due to the complexity of manual operation of a large part of processes computer programmes have been developed to automate certain parts of usage and thus facilitating their use. In order to be able to assess both the processes for an analysis of potential and the method to reduce non-productive times these processes were applied to three selected, real production processes of high-volume production of automotive powertrain components. Rising potentials, and/ or potentials to rise will be covered and explained in detail. The evaluation of the processes to analyse and reduce non-productive times will be conducted using both the potentials identified and additional assessment criteria.