Matrix Production Systems - Requirements and Influences on Logistics Planning for Decentralized Production Structures

In the context of the digital transformation of industry and within the framework of Industrie 4.0 and Factory Planning 4.0, new production-organizational principles with decentralized, modular and freely linked production cells are increasingly being discussed. The principle of matrix production with categorized and standardized workstations offers an extremely versatile production environment. It can be used to meet the challenge of an increasing number of product variants in variable quantities. This concept is predominantly considered from a theoretical point of view. Therefore, many aspects regarding the planning and operation of such systems are still up to debate. With the focus on logistics processes, this paper describes the requirements for such flexible, dynamic routing and self-organizing resources in material supply. Furthermore, they are investigated in a generic, conceptual model for a matrix production. Based on a reference scenario from the automotive industry, classical parameters from logistics and production organization are taken up. The influences with regard to decentralized material supply concepts and structural differences to flow production are shown by the results of simulation experiments with the generic model. 1. Matrix production systems – An example for Industrie 4.0 Industrie 4.0 presents the fourth industrial revolution, which is characterized as a profound change in the field of industrial production through the indentation of the digitalization and networking [1], [2] compared to the previous development stages (mechanization, mass production, automation). The networking includes production resources (machines, facilities, operating equipment, planning, IT, and control systems), as well as the human being (via technical aids). In combination with digitalization and the automation of sensor-based production resources, it is made possible to create a real-time capable, self-organizing value-adding network that is operating company-wide. The development and integration of new technologies is dissolving increasingly rigid corporate structures and control architectures. The given vision ranges from decentralized networks of modular conveyor and warehouse technology to the use of artificial intelligence for smart services in logistics [3]. The resulting increased flexibility and versatility with regard to adjustments (malfunctions, ad hoc production, and material supply adjustments) can be used to proactively give instructions or (automatically) implement measures. Order deviations can thus be controlled without significant production losses, so that there are as far as possible no deviations in terms of quantity, target date, quality, and costs [4]. Due to volatile markets and special customer requirements, there is also an increasing need to produce small batch sizes in an economically viable manner. The challenge is to produce an increasing number of variants and models of a product in variable quantities [5] up to batch size 1. This is where the concept of matrix production or matrix-structured production comes into play, which is characterized by a very flexible and versatile production that is linked together throughout the entire value-added chain [6]. The core element of this novel production-organizational principle are categorized, standardized, and freely interconnected production cells. These cells can be arranged in a scalable number on a production layout. The classic principle of flow production is replaced by a flexible workshop production, and the production process is carried out on production cells, which can each perform various process steps in a highly variable manner. The production cells are not interlinked by a rigid conveyor system. The transportation of the products and materials is mainly carried out by driverless transport systems (AGV) or autonomous mobile robots (AMR) [7]. Logistics processes and manufacturing are decoupled from one Proceedings of the 54th Hawaii International Conference on System Sciences | 2021 Page 1665 URI: https://hdl.handle. net/10125/70813 978-0-9981331-4-0 (CC BY-NC-ND 4.0) another in matrix production. With this concept, the production system with variable parts logistics is always able to switch flexibly to other cells at peak times [5]. Concerning the aspect of flexibility, this results in three new aspects in matrix production [8]:  Executing process steps can be very different due to the individuality of the products (no fixed cycle)  Production cells offer a varying portfolio of process steps depending on the equipment  Process steps are not subject to any fixed constraint of a predetermined sequence due to the abolition of flow manufacturing (depending on product-specific restrictions). On the other hand, this dynamic results in an increased coordination effort of the individual system elements with each other. Overall, the sum of possible individual decisions places higher demands on the control level or the (self-organizing) control system (e.g. the individual, networked autonomous mobile robots (AMR)). Table 1 shows a comparison of the different production organizations. Table 1. Comparison of different Production Or-