1st Edition

Process Oriented Analysis Design and Optimization of Industrial Production Systems

    521 Pages 350 B/W Illustrations
    by CRC Press

    In modern manufacturing, it is not simply the equipment that is increasingly complex but rather the entire business system in which a company operates. Convoluted supply chains, complicated resource flows, advanced information systems: all must be taken into account when designing or reengineering a manufacturing system. Introducing a powerful yet easy-to-follow method, Process Oriented Analysis: Design and Optimization of Industrial Production Systems offers clear and practical guidance on applying this proven analytical technique to any type of manufacturing operation.

    Linking abstract theoretical concepts to real-world implementation, this book outlines the principles of Process Oriented Analysis (POA) and demonstrates the application of these concepts using actual case studies. The authors first present the diagrams and analytical tools used in POA to represent both the static structure and dynamic behavior of the system. They then demonstrate how to build a simulation model by translating the diagram components into usable source code. Software for generating these types of diagrams is available for download from the Internet, along with a thorough tutorial that includes questions and interactive case studies.

    Taking a consistent approach that anyone in the organization can use and understand, Process Oriented Analysis is the perfect resource for planning, designing, debugging, and optimizing modern production systems.


    Process Oriented Analysis
    Concept of POA
    Static Analysis
    Dynamic Analysis
    Setup of a Production Analysis
    Projects Using POA Models
    Organization of the Book
    Delimitation of Process Oriented Analysis
    Upper and Lower CASE
    Structured Analysis
    Unified Modeling Language (UML)
    Computer Support


    Flow Diagram
    Flow Diagram: Why?
    Flow Diagram Elements
    System Boundary
    System Structuring in the Hierarchy
    Element Specification and Data Dictionary
    Setup of a Model and Recommendations
    Application Examples: Gas Station
    Apply Your Knowledge
    Value Flow Diagram
    Value Flow Diagram: Why?
    VFD Elements
    Flow Types and Flow Categories
    Calculation of the Value
    Element Specification and Calculation
    Special Examples
    Application Example: Gas Station
    Apply Your Knowledge
    Resource Flow Diagram
    Resource Flow Diagram: Why?
    RFD Elements
    Flow Types and Flow Categories
    Calculation in the Flow and Process Specification
    Mass Analysis in the RFD
    Energy Analysis in the RFD
    Exergy Analysis
    Embodied Energy Analysis
    Application Example: Gas Station
    Apply Your Knowledge


    State Chart
    State Chart: Why?
    State Chart Elements
    Model Structure
    From Flow Diagram to State Chart
    Recommendation and Guidelines
    Application Example: Gas Station
    Apply Your Knowledge
    Simulation Model
    Simulation Model: Why?
    From Flow Diagram to Code
    Application of Commercial Simulation Packages
    Application Example: Gas Station
    Apply Your Knowledge
    Real-Time Control
    POA for Real-Time Control: Why?
    Machinery States of Manufacturing Processes
    System View in the State Domain
    Program Design and Coding
    Programmable Logic Control of a Fan Heater
    Application Example: Gas Pump
    Apply Your Knowledge


    System Analysis of a Service Enterprise
    Getting to know the Operation of a Bar
    Setting up the Model
    Evaluation Report and Benefits of the Method
    Economical Analysis of a Weaving Mill with Integrated Finishing
    Model of a Production Plant
    Company and Product
    Procedure for Setting up a Model
    Value Flow Diagram of WeaveFine
    Evaluation Report and Benefits of the Method
    Exergy Analysis of an Industrial Bakery
    Energy Analysis of the Croissant Line
    Resource Flow Diagrams of the Croissant Line
    Exergy Balance of the Baking Process
    Benefits of the Method
    System Control for the Demagnetizing of TV Display Tubes
    Demagnetizing of TV Display Tubes
    New Conception of a Demagnetizing Process Line
    System Architecture of the New Production Line
    Process Control for Degauss Production Line
    Benefits of the Method
    Operational Concept for an Automated Plant
    New Production Setup
    What is Texturizing?
    Dynamic Model of the Texturizing Plant
    Simulation Program for the Texturizing Plant
    Results and Benefits of the Model
    Reengineering of a Cable Car
    Cable Car System
    Reengineering of a Transport Process
    Flow Diagrams and State Charts
    Transport Simulation
    Conclusions and Benefit of the Model


    Simone E. Creux, Urs B. Meyer, Andrea K. Weber Marin