Production System Risk Assessment and Loss Categorization Using Simulation Models

The paper presents the concept of risk analysis and assessment in production systems. Due to the complexity of production systems, their complexity and the high degree of integration of individual functional areas, the presented concept assumes the possibility of dividing risk factors into categories. The categories correspond to the functional areas of an enterprise. The Ishikawa diagram and the 4M (machine, material, method, man) categorization were used to determine the categories. According to the concept presented in the paper, risk factors occurring in a production system were assigned to each category. This assignment made it possible to determine the amount of losses in the production system caused by the occurrence of risk factors in individual areas of the production system. Variant simulations and simulation models specially built for this purpose were used to assess the risk of the production system. The results obtained from the experiments on simulation models allowed to determine the time increments and the amount of losses caused by the occurrence of risk factors in individual functional areas of the system. The presented concept was verified on the example of the steel bolster body production process. The data used for the verification comes from the real production process.