Towards the adaptive and economic response to short-term disruptions within resilient manufacturing process chains

The growing demand for flexible, sustainable, and individualized production is giving rise to complex manufacturing systems and comes along with a higher susceptibility to process-related disruptions. Due to the costs associated with disruptions, effective disruption management is increasingly becoming a decisive factor in maintaining and expanding a company’s competitiveness. To increase the resilience of manufacturing systems, it is necessary to develop methods that enable an adaptive and economical response to short-term disruptions. This paper presents a 3-phase approach that reduces the negative impact of disruptions by identifying and evaluating suitable response options within manufacturing process chains. In phase 1, the disturbed actual situation is analyzed using a workpiece and a process model. The models are used in phase 2 to identify suitable response options, while considering capacities and technological interactions along the process chain. The alternatives are then evaluated economically in phase 3. The methodology developed is presented using the validation example of the manufacturing of a shaft.