Matrix Production

In comparison to traditional production systems, the matrix production system stands out due to high versatility, flexibility and resilience. Core elements of the matrix production are freely concatenated manufacturing and assembly stations with multiple process abilities, an intelligent production planning and control system for rapid and dynamic machine scheduling and a flexible transport system. Requirements are the integrated connectivity and the intelligence of the objects part of the value creation process. The free concatenation allows the avoidance of cycle time dispersion and leads to an increase in productivity. A rapid routing flexibility is archived through the redundance of manufacturing and assembly stations and an intelligent material flow control so that disruptions and shortages can be countered with rapid reactions. Instead of a fixed job schedule, the jobs are being approved at short term.

The matrix production combines the economic advantages of a traditional flow production system with the flexibility of a job-shop production. Therefore, the matrix production is suitable for fluctuating demand and high numbers of variants while being robust when disturbances occur. On the other hand, the increased degrees of freedom lead to an increase in complexity of the overall system.

To check, whether the matrix production as a concept for manufacturing is suited for your production, a wide analysis is needed. For the transformation of a traditional flow production to a matrix production, the Fraunhofer IML has developed a maturity level analysis which considers the entire transformation process holistically.  The maturity level analysis actively supports the transformation of your production and can be used to define requirements for the replanning of a versatile production system.

We support the transformation process of your production and collectively develop strategies to implement a matrix production in your company.

Our approach to the conceptional design of your versatile production system

• Holistic analysis of the transformation process for the development of potential transformation paths
• Conceptual design of a rapid, dynamic and efficient supply of production
• Simulation and evaluation of the logistic performance

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Matrix production is THE key to greater flexibility and resilience in your manufacturing operations. Let’s explore the possibilities for your production together and take the first step toward an adaptable future.

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The growing importance of the circular economy, remanufacturing, and industrial repair is increasingly affecting existing production systems. Unlike traditional manufacturing, processes in circular value chains are often characterized by uncertainty: the condition, variants, and required processing of returned products vary greatly and often only become fully apparent during disassembly.

In particular, this means that traditional planning and control approaches often reach their limits in remanufacturing and disassembly processes, as they are designed for stable and predictable process chains.

Challenge: High uncertainty in processes

Especially in disassembly and remanufacturing, it is often not known in advance

• which components need to be processed,
• which process steps are required, and
• how long these will take.

Conventional, linearly linked production systems quickly reach their limits here, as rigid workflows and cycle times lead to inefficiencies.

Solution Approach: Matrix Production and Flexible Routing

Matrix production systems offer decisive advantages for circular applications due to their decoupled structure.

By eliminating rigid line sequencing and fixed cycle times, they enable:

• flexible routing of products based on individual needs
• demand-driven use of resources
• avoidance of cycle time variations

This allows different processing scopes to be efficiently accommodated.

Our approach

We support companies in designing circular value chains through:

• analysis of return-to-line and process variabilities
• development of flexible routing and control concepts
• Application of matrix principles to disassembly and remanufacturing processes
• Design of high-performance and robust system structures

Your benefits

• Higher productivity despite variable processes
• Efficient management of uncertainties
• Increased resource utilization
• Future viability of production structures for the circular economy

Start your circular transformation here

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