In the last five years, the consumer market for fruit juices and fruit beverages has experienced increasing competition. The industry has to supply higher quality, larger variety, and better packaging at more competitive prices. From a manufacturing point of view, very high service levels have to be combined with short product lead times. Together with the strongly increased product variety this has set new performance standards for the manufacturing of canned fruit juice beverages.
Although a large variety of detailed design methods for a specific subset of design problems is available, literature does not present a universally accepted method for designing a fruit juice blending and packaging plant. Furthermore, literature disregards the fact that an industrial system evolves throughout its life-cycle and that optimizing and redesigning are essential tasks in the design process. Finally, although design of control and manufacturing system show a great deal of interaction, literature treats them separately. Integrating design of control and manufacturing system in one method can enhance the performance of the industrial system.
The objective of this dissertation is to provide a design method that structures the design process of fruit juice blending and packaging plants. This method is composed of a structure and a set of tools. The structure tells the user which design decisions need to be made and when to make them. The tools support the decision making process. The structure is generally applicable; the set of tools makes the design method specifically suitable for the design of fruit juice blending and packaging plants. The proposed design method incorporates design of the manufacturing system as well as design of the control system, where it affects the manufacturing system. It supports initial design as well as redesign of the plant operations.
The design method consists of four phases: objective definition, design of architecture, design of resources, and design of operations. First, the objectives and constraints are defined. Then, the architecture of the manufacturing and control system is designed. A first order approximation of the necessary resources is determined in the design of resources. Detailed design of the manufacturing system and control system is done in the design of operations.
The design method has been used to support a redesign project for Riedel's production facility. The production is divided in three successive stages: preparing, pasteurizing, and packaging. For juice preparation, a group technology structure is applied; for pasteurizing and packaging, a flow line structure is applied. In the design of resources, these structures are quantified. To support this process, two design tools have been developed. The result of the design of resources is a list of resources and a factory layout. In the design of operations, the resource design is refined and the control system is designed. To support design activities in this phase, two scheduling algorithms have been developed, and integrated in a design tool. This tool supports evaluation of `what if' scenarios and the construction of detailed production schedules.
Ph.D. thesis, Eindhoven University of Technology, 2000.