Managing Complex Interactions between Production and Failure Management: a System-theoretical Model

This paper introduces and tests a system-theoretical model considering the complex interactions between operational production goals and reactive failure management. In particular, reactive failure management tasks are emphasized, including the analysis and correction of failures and their effects on production goals. For the determination of the proportionate influence of failure management on production, a system-theoretical model is developed. All production chains are represented by linking five modules (resources, production, defect introduction, root cause elimination and defect-based learning). This comprehensive modeling of modules enables the consideration of corresponding variables of production planning and control. A stock and flow diagram is used as an adequate means of description and visualization. Further, the formal model is converted into an executable simulation model. The verification and validation of the model are accomplished by reviewing specific aspects of all phase results. Tests performed on the final simulation model are described. Therefore, this paper improves the understanding of the complex relationship between production goals and handling failures and proves the importance of well-structured failure elimination processes.