A SCENARIO ANALYSIS ON THE EFFECT OF INDUSTRY 4.0 ON INVENTORY COSTS IN PRODUCTION SYSTEMS

Year 2020, Issue: 2, 125 - 143, 18.03.2020

Sedat Belbağ Mustafa Çimen Mehmet Soysal

Abstract

In a growing competitive environment, Industry 4.0 represents a total autonomous production concept where companies take advantage of technologies such as internet of things, cyber-physical production systems, 3-D printers, smart machines and storage systems to eliminate human factor from production processes. In parallel with the development of Industry 4.0, smart production systems are superior to traditional production systems in various ways such as high productivity and capacity usage. Moreover, a considerable amount of investment is required in the configuration phase of smart production systems. Low capacity flexibility might prevent smart production systems to satisfy the demand that exceeds the predetermined capacity. This study compares the intelligent production system with the traditional production system by taking into account the order quantity and scheduling problem under the assumptions of multiple product production and sequence dependent preparation costs in the finite planning horizon. The study aims to determine the cases where smart production systems are advantageous and disadvantageous with respect to inventory costs. The analysis shows that the degree of benefit from the increase in productivity with fully automated machines in intelligent production systems is closely related to determining the correct capacity.

Keywords

Industry 4.0, Smart Production System, Lot-Sizing and Scheduling Problem, Sequence-Dependent Setup Cost

ÜRETİM SİSTEMLERİNDE ENDÜSTRİ 4.0’IN ENVANTER MALİYETLERİNE ETKİSİ ÜZERİNE BİR SENARYO İNCELEMESİ

Abstract

Endüstri 4.0, artan küresel çaptaki rekabet ortamında üretim işletmelerinin nesnelerin interneti, siber-fiziksel üretim sistemleri, üç boyutlu yazıcılar, akıllı makineler ve depolama sistemleri gibi teknolojileri kullanarak insan faktörünün ortadan kaldırıldığı tamamen otonom bir üretim anlayışını temsil etmektedir. Endüstri 4.0‘ın gelişimi ile paralel olarak, akıllı üretim sistemleri başta yüksek verimlilik ve kapasite kullanım oranı gibi birçok açıdan geleneksel üretim sistemlerine üstünlük sağlamaktadır. Diğer yandan, akıllı üretim sistemlerinin kurulum aşamasında yüksek miktarda yatırım gerekmektedir. Düşük kapasite esnekliği akıllı üretim sistemlerinin önceden belirlenen kapasitenin üstündeki talepleri karşılamasını engelleyebilmektedir. Bu çalışma, akıllı üretim sistemi ile geleneksel üretim sistemini sonlu planlama ufkunda birden çok ürün üretimi ve sıra bağımlı hazırlık maliyeti varsayımlarını altındaki bir sipariş miktarı ve çizelgeleme problemini dikkate alarak karşılaştırmaktadır. Çalışmanın amacı, akıllı üretim sistemlerinin hangi durumlarda envanter maliyetleri açısından avantajlı, hangi durumlarda dezavantajlı hale geldiğini tespit etmektir. Yapılan analizler, akıllı üretim sistemlerindeki tam otomasyona sahip makineler ile verimlilikteki artıştan sağlanacak faydanın derecesinin doğru kapasite belirlenmesi ile yakından ilişkili olduğunu ortaya koymaktadır.

Keywords

Endüstri 4.0, Akıllı Üretim Sistemi, Sipariş Miktarı ve Çizelgeleme Problemi, Sıra-Bağımlı Hazırlık Maliyeti

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