Material flow analysis

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As a material flow analysis refers to the detection of the transport processes and procedures, as well as bearings and unwanted stays all materials in a company. The aim of this analysis is to identify weak points in the material flow and to research their causes. In addition, it enables the determination and assignment of material flow costs to the areas involved. The flow of materials is a significant cost and time-consuming factor. Therefore, the material flow analysis is also considered to be of great strategic importance.

The graphic representation of material flow systems serves to highlight and clarify relationships and processes in order to show specific data and weak points and to be able to assess them more easily.

Basics

A graphic representation offers the advantage of a better overview and ensures that the essentials can be recorded quickly.

The most important elements of the presentation are:

  • Internal quantity centers: e.g. B. Warehouses, processing points, production areas, production facilities, etc.
  • External quantity centers: e.g. B. Suppliers , contract manufacturers , customers , disposal companies
  • Material flows: regular material movements from one material location to another
  • System boundary: defines the boundary area under consideration and separates internal material locations from external ones.

In a representation, a distinction can be made between a qualitative and a quantitative material flow.

  • The representation of the qualitative material flow is based on the routings and only shows transport lanes, but not quantities. This reduced form of display is used particularly in the case of highly branched transport lanes, as it promotes clarity.
  • When displaying the quantitative material flow , the qualitative material flow is supplemented by production quantities.

Data collection

From-to matrix: quantities moved between five material locations in a company
Pie chart: shows the proportions of three proportions to one another

Before a meaningful graphic can be created, data about the personnel involved in the material flow, material, area and means of transport and storage must be collected. The generated information can be illustrated with the aid of mathematical representation methods. Examples are assignment tables , from-to matrices (see below), questionnaires, question lists , VDI material flow sheets , evaluation matrices and weighting matrices.

In the from-to matrix , the material locations are assigned moving quantities, costs, time units, etc., which were obtained through the data collection.

However, graphic display methods, in particular diagrams , are also used to visualize the data obtained: B. Bar chart , column chart , bar chart, pie chart , line chart, curve chart . The diagrams listed here are used to show structures in the types of material, classifications, proportions of proportions or, in some cases, dependencies between the materials.

Another example is the histogram , which can be used to display frequencies in particular. The Sankey diagram can also be used to illustrate material flows according to quantities.

variants

qualitative material flow in a rough layout
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In order to represent the movement sequence of the material flow, methods are required that can illustrate temporal dependencies (one after the other, parallelism or independence), causal relationships, directions, chaining, branching of relationships, etc. One possibility is to represent the process with the help of a flow diagram , such as the Sankey diagram.

In the Sankey diagram , relationships between the equipment and, at the same time, their directions are shown by arrows. Since the Sankey plan shows quantitative material flows, their intensity (production quantities) can also be seen from the width of the arrows. Due to the increased complexity of the type of representation, it is unusable in the case of very complex relationships and even with a large number of material flows. As a rule, a Sankey plan is only drawn up for main material flows (only relatively regular material flows relevant to the company). The figure on the right shows the facts of the from-to matrix described above using a Sankey plan.

Further variants are: bar diagram , material flow plan , work flow plan, function plan and block diagram. Directed material flows, as they predominate in the production of technical products (e.g. in the automotive industry), can also be described with the help of Boolean intervals (see also Boolean algebra ). In connection with parts lists, they can be used to plan and control material flows in complex production chains and in supply chain management .

Often the representation of qualitative or quantitative material flows takes place directly in the (rough) layout. This method is one of the two-dimensional drawings and enables fundamental problems in the river system to be identified at an early stage. Here, too, only the main material flows are shown.

Individual evidence

  1. ^ Heinrich Martin: Transport and warehouse logistics. 4th edition. Vieweg, 2002, ISBN 3-528-34941-7 , p. 403.
  2. ^ Heinrich Martin: Transport and warehouse logistics. 4th edition. Vieweg, 2002, ISBN 3-528-34941-7 , p. 29.
  3. ^ W. Herlyn: PPS in automobile construction. 2012, p. 131 ff.

literature

  • Dieter Arnold, Kai Furmans: Material flow in logistics systems. 5th edition. Springer 2007, ISBN 978-3-540-45659-9 .
  • Klaus Bichler, Norbert Schröter: Practice-oriented logistics. 3. Edition. Stuttgart 2004, ISBN 3-17-018147-5 .
  • Harald Ehrmann: Logistics. 4th edition. Kiehl 2003, ISBN 3-470-47594-6 .
  • Heinrich Martin: Transport and warehouse logistics. 4th edition. Vieweg 2002, ISBN 3-528-34941-7 .
  • Ali Yacooub, Johannes Fresner: Half is Enough - An Introduction to Cleaner Production. Self-published, Beirut 2006, ISBN 3-9501636-2-X .
  • Johannes Fresner, Thomas Bürki, Henning Sittel: Resource efficiency through cleaner production. 1st edition. Symposium Publishing, 2009, ISBN 978-3-939707-48-6 .
  • W. Herlyn: PPS in automobile construction - production program planning and control of vehicles and assemblies . Hanser Verlag, Munich 2012, ISBN 978-3-446-41370-2 .
  • Paul H. Brunner, Helmut Rechberger: Handbook of Material Flow Analysis: For Environmental, Resource, and Waste Engineers. 2nd Edition, CRC Press, 2016, ISBN 9781498721349 .

Web links