3 ways in which the Holonic Manufacturing Systems inspires WCM 4.0

Figure: Relationship between HMS and WCM 4.0

A natural hierarchy is simply an order of increasing wholeness. Components make up a machine, and machines make up a manufacturing plant. The whole for one level makes up a part for the next. Basically, natural hierarchies are composed of holons. The Holonic Manufacturing System (HMS) consists of holarchies which is a hierarchical model for resources, order and products in the manufacturing environment presented in an inverted pyramid model.

The word holon is a combination of two Greek words holos which means “whole” and on which means “part” as in proton. A holon in the manufacturing environment consists of an autonomous and cooperative block that has an information handling part and a physical transformation part. The Holonic manufacturing system has been used to rise above challenges in the manufacturing control systems through versatility and agility. It also brings about stability to overcome disruption, adaptability and flexibility in the face of change and efficient use of available resources.

The World Class Manufacturing 4.0 (WCM 4.0) is presented in a delta model which is composed of employee solutions, process lock-in and equipment optimization with Meta physical systems at its heart. The WCM 4.0 Model is thus advanced synergistic combination of the traditional world class manufacturing structure and the now becoming obsolete cyber physical system. When was the last time you were in a cyber café? The WCM 4.0 Model, like the HMS Model brings about easy self-configuration, extension and modification of systems thus allow for flexibility and decision autonomy for higher control levels.

HMS is alive to the fact that the behavior of the elements in the holons do not act in a pre-determined manner and though they may integrate themselves to form a structure they seek to preserve their autonomy as self-contained units. From this, the HMS brings in litheness and quick reaction in WCM 4.0 systems. The HMS has holarchies defined in three distinct holons (building blocks), they are one, resource holon, two, order holon and three, product holon.

In the synergistic combination of the WCM 4.0 and the HMS the resource holon holds in abstraction employee solutions and equipment optimization to drive production. The order holon, gives direction to manufacturing sequence through employee solutions and process lock-in while the product holon enhances product quality through process lock-in and equipment optimization. The manufacturing industry is Knowledge based and heavily relies on skills and technical know-how to achieve these objectives.

Below are the three ways the HMS influences WCM 4.0.

#1: Process Execution Knowledge

The process execution knowledge is the information and methods in application of resources within the manufacturing set up. It aims at integrating humans with software and hardware, as such, it is knowledge that enables the start of utilization of resources, the reserving of resources, the monitoring of the progress on deployment of resources, how to interrupt the application of resources, consequences of interrupting the use of resources, suspending and resuming the processes on resources and anything else that deals with expending of resources.

The process execution knowledge directly affects the employee solutions element of the WCM 4.0 model. The process execution knowledge in the traditional WCM structure are; group activities, six S (Safety, Sort, Shine, Set-in place, systemize and sustain), visual management, focused improvement, office and administration, safety, health and environment, and people development.

Process execution Knowledge in WCM 4.0 analyzes the deployment of new employee solutions and assessing the changes in the manufacturing environment vis other organization stakeholders. It exposes the forces that drive employee and shareholder interests and the motivation to co-develop employee solutions that refines the solutions offered with time.

Employees present problems,while stakeholders respond on the basis of not only the feasibility of the employee-specific solution but also their analysis of future solutions in the manufacturing environment, the stakeholders then aim to standardize successful solutions across the manufacturing facility. Novel solutions have an executing shaping effect and can evoke reactions from actors who want to enhance their manufacturing position.

#2: Product Knowledge

Product knowledge is the information and methods on how to manipulate a given product with definite resources, it looks at the possible sequences of operations that need to be applied, data structures that are significant to the outcome and methods of accessing information relevant to the process.

The product knowledge is the bridge between the order holon and the product holon, thus this portion of the HMS influences the process lock-in in WCM 4.0. In WCM 4.0 product knowledge is built through visual management, product management, quality maintenance and focused improvement. While product knowledge in HMS looks into operations that need to be performed so as to achieve a quality product, WCM 4.0 seeks to sustain and innovate processes that build quality into the product.

The HMS enables the process lock-in to manage the physical outcome of the processes, the final outcome state and model and all logistical information processing related to the outcome. This brings about product flexibility and customization. From a HMS perspective the WCM 4.0 process lock-in may be boxed into the production processes but this may not be the case as it views all operations within the manufacturing set-up i.e. human processes, production processes and equipment processes.

#3: Process Knowledge

Process knowledge is the information and methods relevant to performing a definite process using a given resource. It is knowledge about the capabilities of the resource, which operations it can perform and the appropriate process parameters necessary to achieve a given outcome. The process knowledge directly influences WCM 4.0 equipment optimization.

The process knowledge is the link between the product holon and the resource holon as such it aims at minimizing cost per unit and achieve production deadlines through effective use of the resources available in the organization. Process knowledge empowers equipment optimization through improvement of the facility equipment layout, identifying which production processes need to be outsourced, offering multiple ways of making a product, enabling reconfiguration of equipment’s and building capacity for handling high volume low variety and low volume high variety products.