Flexibility Measurement in Production Systems	4
	Author´s Note	6
	Contents	8
	List of Abbreviations and Acronyms	12
	Chapter 1: Introduction	14
	1.1 Importance of Flexibility in Production	14
	1.2 Current Trends in Handling Flexibility in the Field	16
	1.3 Objective of This Book	19
	Chapter 2: Analysis of the Field of Observation	22
	2.1 Production Systems	22
	2.1.1 Definition of Terms	22
	2.1.2 Resources of a Production System	24
	2.1.2.1 Production Equipment	24
	2.1.2.2 Personnel	26
	2.1.2.3 Material	27
	2.1.3 Observation Levels in Production Systems	28
	2.1.3.1 Workplace Level	29
	2.1.3.2 Line Level	30
	2.1.3.3 Segment Level	32
	2.1.3.4 Factory Level	33
	2.1.4 Change Drivers and Adaptation Objects of Production Systems	34
	2.2 Flexibility of Production Systems	36
	2.2.1 Application of Terms and Dimensions of Flexibility	37
	2.2.2 Classification of Flexibility	40
	2.2.3 Relevant Criteria for Flexibility Evaluation on Production Systems	43
	2.2.3.1 Definition of Volume Flexibility	43
	2.2.3.2 Definition of Mix Flexibility	44
	2.2.3.3 Definition of Expansion Flexibility	44
	2.3 Analysis of Relevant Evaluation Methodologies for Measuring Flexibility of Production Systems	44
	2.3.1 Evaluation Methodology by Zäh and Müller	45
	2.3.2 Evaluation Methodology PLANTCALCTM	46
	2.3.3 Evaluation Methodology by Wahab, Wu und Lee	47
	2.3.4 Evaluation Methodology by Schuh, Gulden, Wernhöner and Kampker	47
	2.3.5 Evaluation Methodology by Ali and Seifoddini	48
	2.3.6 Evaluation Methodology Desyma	49
	2.3.7 Evaluation Methodology by Pelez-Ibarrondo und Ruiz-Mercader	50
	2.3.8 Evaluation Methodology Penalty of Change	50
	2.3.9 Evaluation Methodology by Haller	51
	2.3.10 Evaluation Methodology FLEXIMAC	52
	2.4 Need for a New Methodology and Requirements	53
	2.5 Requirements for a New Evaluation Methodology	55
	2.5.1 Fundamental Applicability	56
	2.5.2 Flexibility Metrics	57
	2.5.3 Production System Model	58
	2.5.4 Software Implementation	59
	Chapter 3: Introduction of a New Evaluation Methodology	60
	3.1 Fundamental Approach for the Evaluation of Volume-, Mix- and Expansion Flexibility	60
	3.1.1 Evaluation Proposal for Volume Flexibility	61
	3.1.2 Approach to Evaluation of the Mix Flexibility	62
	3.1.3 Evaluation Approach to Expansion Flexibility	63
	3.1.4 Comparative Consideration and General Conditions of the Evaluation	65
	3.2 Calculation Procedure for the Measurement of Flexibility	68
	3.2.1 Base Algorithm	68
	3.2.1.1 Defining the Calculation Parameters (Step 1)	69
	3.2.1.2 Formulation of the Objective Function (Step 2)	71
	3.2.1.3 Formulation of the Constraints (Step 3)	73
	Time Conditions	73
	Ratio Conditions	75
	3.2.1.4 Formulation of the Linear Optimization Problem (Step 4)	79
	3.2.1.5 Solution of the Optimization Problem (Step 5)	80
	3.2.2 Flexibility Evaluation Method of Volume flexibility	81
	3.2.2.1 Maximum Capacity	81
	Calculation of the Maximum Capacity for the Whole System	81
	Calculation of the Maximum Capacity for Subsystems	83
	3.2.2.2 Break-even Point	85
	Calculation of the Break-even Point for the Whole System	85
	Calculation of Break-even Points for Subsystems	87
	3.2.2.3 Calculation of the Volume Flexibility	90
	3.2.3 Flexibility Evaluation Method of Mix Flexibility	92
	3.2.3.1 Calculating the System-Optimal Production Profit	92
	3.2.3.2 Calculating the Product-Limited Profit Optimum	95
	3.2.3.3 Calculation of the Mix Flexibility	96
	3.2.4 Flexibility Evaluation Methodology of Expansion Flexibility	98
	3.2.4.1 Calculation of the Target Capacity	98
	3.2.4.2 Calculating the Alternative-Specific Break-Even Point	100
	3.2.4.3 Calculating the Expansion Flexibility	100
	3.3 Definition of the Cost Accounting Reference Frame	102
	3.3.1 Choice of a Cost Accounting Procedure	102
	3.3.1.1 Decision Between Full Cost and Direct Cost Accounting	103
	3.3.1.2 Choice of a Direct Cost Accounting Procedure	104
	3.3.2 Determining the Hierarchies of Reference	104
	3.3.3 Definition of Basic Cost Types	105
	3.3.3.1 Workplace Level	106
	3.3.3.2 Line Level	109
	3.3.3.3 Segment Level	111
	3.3.3.4 Factory Level	112
	3.3.3.5 Graphical Summary of the Cost Types	114
	3.3.4 Classification of Defined Cost Types in Cost Categories	114
	3.3.4.1 Determining Variable Costs	114
	3.3.4.2 Determining Fixed Costs	116
	3.4 Concept of the Production System Model	118
	3.4.1 The Object-Orientated Reference Model	118
	3.4.2 The Principle of Inheritance of the Reference Model	119
	Chapter 4: Practical Experience in the New Methodology	121
	4.1 Implementation of the Evaluation Methodology	121
	4.1.1 Software Architecture of ecoFLEX	121
	4.1.2 Implementation of ecoFLEX	124
	4.1.3 Functionality of ecoFLEX	126
	4.1.3.1 Structure of the Program Window	126
	4.1.3.2 Procedure of Flexibility Analysis	128
	4.2 Case Study-Related Application Experience	130
	4.2.1 Initial Situation at the Company	131
	4.2.2 Object Area of the Case Study	131
	4.2.3 Application of the Evaluation Methodology in the Context of the Case Study	134
	4.2.3.1 Analysis of Volume Flexibility	135
	4.2.3.2 Analysis of Expansion Flexibility	136
	4.2.3.3 Analysis of the Mix Flexibility	138
	4.2.3.4 Appraisal of Flexibility Analysis	140
	4.3 Requirement Related Assessment of the Evaluation Methodology	141
	4.3.1 Verification of the Software Implementation	142
	4.3.2 Verification of the Production System Model	143
	4.3.3 Verification of Flexibility Metrics	145
	4.3.4 Verification of the Fundamental Applicability	147
	Chapter 5: Summary and Outlook	152
	5.1 Summary	152
	5.2 Outlook	157
	Chapter 6: Appendices	159
	6.1 Basic Knowledge	159
	6.1.1 Methods of Cost Accounting	159
	6.1.1.1 Classification Criteria of the Cost Accounting System	159
	6.1.1.2 Full Cost Accounting	160
	Level 1: Cost Type Accounting	161
	Level 2: Cost Centre Accounting	161
	Level 3: Cost Object Accounting	162
	6.1.1.3 Direct Cost Accounting	162
	Direct Cost Accounting System Based on Variable Costs with Global Consideration of Fixed Costs	163
	Direct Cost Accounting System on the Basis of Variable Costs with Differentiated Consideration of Fixed Costs	164
	Direct Cost Accounting System on the Basis of Relative Direct Costs	166
	6.1.2 The Simplex-Algorithm	167
	6.1.3 Object Orientation	169
	6.1.3.1 The Object Orientated Approach	169
	6.1.3.2 Relevant Principles and Different Kinds of Representation in Object-Orientation	171
	6.2 Additional Methods for Calculating of Flexibility	173
	6.3 Demonstration of Further Aspects Regarding the Evaluation Methodology	175
	6.3.1 Calculation of Energy Costs for Workplaces	176
	6.3.2 Process Time as Part of the Cycle Time	177
	6.4 Example of a Production System (for Illustrating Flexibility Calculations)	178
	6.4.1 Graphical Structure and Terms	178
	6.4.2 Calculating Parameters of the System	179
	6.4.3 Expansion Alternatives for Segment S2	180
	6.4.3.1 Alternative 1: Construction of a Redundant Production Line	180
	6.4.3.2 Alternative 2: Construction of an Additional Workplace	181
	6.4.3.3 Alternative 3: Modification of Workplaces	182
	6.5 Calculation Parameters of the Expansion Activities from the Example Production System	182
	References	184
	Index	194