A framework for performance measurement during production ramp-up of assembly stations

Production ramp-up is an important phase in the lifecycle of a manufacturing system which still has significant potential for improvement and thereby reducing the time-to-market of new and updated products. Production systems today are mostly one-of-a-kind complex, engineered-to-order systems. Their ramp-up is a complex order of physical and logical adjustments which are characterised by try and error decision making resulting in frequent reiterations and unnecessary repetitions. Studies have shown that clear goal setting and feedback can significantly improve the effectiveness of decision-making in predominantly human decision processes such as ramp-up. However, few measurement-driven decision aides have been reported which focus on ramp-up improvement and no systematic approach for ramp-up time reduction has yet been defined. In this paper, a framework for measuring the performance during ramp-up is proposed in order to support decision making by providing clear metrics based on the measurable and observable status of the technical system. This work proposes a systematic framework for data preparation, ramp-up formalisation, and performance measurement. A model for defining the ramp-up state of a system has been developed in order to formalise and capture its condition. Functionality, quality and performance based metrics have been identified to formalise a clear ramp-up index as a measurement to guide and support the human decision making. For the validation of the proposed framework, two ramp-up processes of an assembly station were emulated and their comparison was used to evaluate this work.