Simulation-based dimensioning of manufacturing process chains

Manufacturing process chains represent a sequence of specifically arranged, single processes to assure the production of a part. In the past, the focus lied on the optimisation of the individual processes in terms of lead or setup times and efficiency. These approaches disregarded the benefits which can be gained from the consideration of the existing interactions between the processes. Yet, it is very unlikely to achieve the holistic optimum of a process chain using this approach. Instead, a perspective shift is required which on the one hand leads to a higher system complexity to be handled but on the other hand leads to more promising results and harmonised processes. By implementing the definition of technological interfaces between the processes, a link between the processes is established and the effect of each parameter change on the performance of the subsequent processes can be modelled and assessed. In doing so, a general optimisation of the entire process chain can be obtained. In the presented paper, a simulation-based approach for modelling and dimensioning process parameters in a process chain as well as the corresponding technological interfaces is introduced to the reader. First statements about the optimal parameter settings for a holistic optimum of the process chain are derived by setting up a simulation of a reference process chain for pinion shaft production based on precision forging technology. In a second step, a discriminant analysis is applied as an alternative optimisation approach and evaluated for the presented production of pinion shafts.