Fundação Araucária; CNPq; RENAULT; Seti / As linhas de montagem que envolvem soldagem por pontos estão amplamente presentes na indústria de fabricação automotiva. O processo de montagem da estrutura do veículo emprega vários robôs equipados com ferramentas de soldagem por pontos. Estes robôs e ferramentas possuem altos custos, fazendo surgir a necessidade de projetar a linha cuidadosamente, atendendo à demanda do produto e reduzindo as despesas ao mesmo tempo. Nesta dissertação, propõe-se e estuda-se o problema do Projeto de Linha de Montagem Robótica (PLMR), com base nas características práticas de uma empresa automotiva localizada no Brasil. Desenvolve-se um modelo de Programação Linear Inteira Mista (PLIM) que permite: (i) paralelização de estações, (ii) seleção de equipamentos e (iii) múltiplos robôs por estação de trabalho. O modelo matemático visa minimizar o custo total à uma taxa de produção desejada, o que envolve robôs, ferramentas e instalações. O modelo proposto considerou o tempo morto durante um ciclo, restrições de espaço, restrições de alocação de tarefas e possibilidades de paralelismo. O tempo morto é um tempo improdutivo e fixo do trabalho de manuseio de peças que acompanha o tempo de movimento dos robôs transportadores capacitados. Experimentos computacionais foram realizados para evidenciar a influência dos parâmetros sobre a solução ótima do projeto de linha. Além disso, foram realizados estudos de casos práticos com parâmetros reais coletados de uma linha de montagem robotizada para soldagem, localizada na região metropolitana de Curitiba-PR, chegando à otimalidade. Em comparação com as linhas estritamente seriais, o modelo mostrou grandes vantagens ao permitir paralelizar as estações no sistema de produção, permitindo avaliar uma compensação entre a taxa de produção e o custo total. / Spot welding assembly lines are widely present in the automotive manufacturing industry. The procedure of building the vehicle’s body employs several robots equipped with spot welding tools. These robots and tools are quite costly, arising the necessity of designing the line consciously, meeting the product demand and reducing expenses at the same time. In this master thesis, the Robotic Assembly Line Design (RALD) problem is proposed and studied based on practical characteristics from an automotive company located in Brazil. A Mixed-Integer Liner Programming (MILP) formulation is developed allowing: (i) station paralleling, (ii) equipment selection, and (iii) multiples robots per workstation. The mathematical model aims at minimising the total cost at the desired production rate, which involves robots, tools and facilities. The proposed model considered dead time during a cycle, space constraints, task assignment restrictions, and parallelism possibilities. Dead time is an unproductive and fixed work-piece handling time that accompany the capacitated transporter robots’ movement time. Computational experiments were performed in order to evidence the parameters’ influence over the optimal line design solution. In addition, practical case studies were conducted with parameters collected from a real-world robotic welding assembly line located on the outskirts of Curitiba-PR (Brazil), reaching optimality. Compared to the strictly serial lines, the model led to great advantages by allowing station paralleling in the production system, making it possible to evaluate an expected trade-off between the production rate and the total cost.

Uma das atividades mais rentáveis conduzidas pelas indústrias da atualidade é o desenvolvimento de novos produtos. Uma das etapas a serem consideradas no desenvolvimento de novos produtos é a definição do processo de fabricação do produto. Nas etapas iniciais do processo de desenvolvimento de produto, a definição dos processos relacionados é realizada de maneira estimativa. Somente quando da industrialização do produto é que realiza-se o estudo de tempos de produção, leiaute, entre outros. Deste modo, diversas composições de processo que poderiam ser implementadas são ignoradas, porque estas somente serão estudadas em futuros aperfeiçoamentos do processo produtivo. Diversos estudos tem sido conduzidos, voltados para a otimização do processo, em termos de balanceamento de linha, tempos de produção e leiaute. Entretanto observa-se que, nas etapas iniciais de desenvolvimento do produto, o processo de fabricação não é corretamente endereçado, sendo realizados apenas estudos superficiais. O objetivo do presente trabalho é construir um modelo para definição mais precisa dos processos produtivos a partir do projeto de produto. Para tal, foi realizada a revisão da literatura quanto a projeto do produto e otimização do processo, abordando quatro principais temas: i. estudo de tempos; ii. balanceamento de linha; iii. desenvolvimento de leiaute; iv. conceitos de manufatura enxuta; por serem estes os que mais impactam no processo de tomada de decisão. Com base no referencial teórico, desenvolveu-se um modelo para a definição de processo de forma otimizada, na etapa inicial do desenvolvimento de produto. Um estudo de caso em uma empresa do ramo automobilístico foi conduzido para verificar a viabilidade do modelo, comparando os resultados obtidos pelo modelo atual de desenvolvimento de processo contra o modelo proposto por este trabalho. Os resultados obtidos indicam que o modelo adere à realidade, permitindo uma definição robusta do processo fabril, ainda em estágios iniciais do PDP.

The thesis is concerning rotator assembly at Indexator. A need to increase production has been seen and it can be done by implementing an optimized assembly process. In addition to the assembly process a new design on workstations and new test equipment is needed.The study resulted into three assembly process proposals. The processes were balanced, layouts were produced and Plant simulation was utilized to produce simulation models. Each proposal were analyzed based on cost, performance, ease of implementation, flexibility and worker condition. This resulted in a stationary assembly process being most promising and a 3D simulation model was produced for visualization and better understanding. The stationary assembly process has a capacity for 90 rotators per day, while reducing the amount of workers by one.The layout of the workstations was done based on the assembly process layout and further developed to make the work cell lean and ergonomic. It resulted in three workstations to perform the assembly. The test bench was developed by creating target specifications, establish a test procedure and decide components for the test bench layout. The finished test bench can measure dynamic torque, count particles to ensure cleanliness and is able to run the test unattended. / Examensarbetet handlar om montering av rotatorer på Indexator. Målet är att ta fram en optimerad monteringsprocess som kan implementeras i Indexators fabrik utan svårigheter. Den nya monteringsprocessen kommer kräva en ny design på arbetsstationerna och nya testbänkar.Fyra koncept på monteringsprocessen togs fram, baserat på monteringens behov och målsättning. Efter utvärdering så modifierades de fyra koncepten till tre förslag på monteringsprocesser. Processerna balancerades, layouter utvecklades och simuleringsmodeller producerades för varje process. Varje förslag analyserades baserat på kostnad, prestanda, implementation,flexibilitet och arbetar-förhållande. Resultatet blev en stationär monteringsprocess och en 3Dsimulering gjordes för visualisering och förståelse. Den stationära monteringsprocessen har en kapacitet på 90 rotatorer per dag och reducerar behovet av montörer.Layouten för monteringsstationerna baseras på processens layout och har modifierats för ergonomiska aspekter. Inom monteringsstationerna så utvecklades layouten för att minimera antalet onödiga rörelser för montören. Testriggens design utvecklades genom att analysera de behov som fanns, skapa en kravspecifikation samt utvärdera och besluta om testprocedur, upplägg för testrigg och dess ingående komponenter. Testriggen uppfyller målsättningen som är att kunna mäta dynamiskt vridmoment, räkna partiklar för att säkerställa renhet i rotatorn och kunna utföra testningen självgående för att frigöra montören under testprogrammet.

This Master's thesis deals with the optimilization of the production process of the firm ADC Czech Republic s.r.o. The first part the tesiis focused on the research study of the issue, which is used in the practical part. The second one is devoted to brief introduction of the company ADD Czech Republic and the introduction of the product, that is engineered on the production line. The next chapter is divided into three parts. The first chapter creates an analysis of actual condition. The second deals with the implementation of the proposial. Finally, the third part is focused on other possible proposals, which have not been properly worked out

This diploma thesis deals with customer complaints of headlamps in Automotive Lighting s.r.o. The goal is to analyze the state of customer complaints for 2018 and to evaluate the biggest source of nonconformities in terms of the type of complaint based on Pareto analysis. The thesis focuses on solution of one particular type of complaint. The key part of the thesis is also the processing of the process analysis, the evaluation of the causes of the complaint and the draft of corrective measures that would eliminate the problem. The conclusion of the thesis contains evaluation of the proposed corrective measures, including from the economic point of view.

In opening, this diploma thesis is introducing the company Daikin Device Czech s.r.o. In the next step the principle of function of a heat pump. Then there are described its main parts. First part of this thesis is dedicated to assembly line of the heat pump’s switchboxes. The layout of the assembly line is described and added with description of used health and quality measures. Main part is speaking about running test of the switchbox line. The main function of the test is described alongside with description of the process of making the testing software.

This master’s thesis solves the lean production’s methods implementation in the steps assembly department at the company IFE CR, a. s. The first part of the thesis describes the material and information flows and the most serious problems are identified in this part. On the basis of the analysis the optimized future state is designed and possible proposals of solutions are recommended to do for achieving this state. The solution of implementation of a new steps assembly line is solved in detail in the last part.

In the light of the increasing demands and competition in the automotive industry to rapidly introduce new products to the market, management of production ramp-ups and production ramp-downs has become a new decisive competitive factor. For this reason, a well-designed strategy has become essential to succeed. For Scania Engine Assembly, this novel challenge is underway in the form of a ramp-down of the old assembly line (DL) and simultaneous ramp-up of the new assembly line (DW). This is to deliver the new and more sustainable engine platform Super. DL consists of a basic assembly and a final assembly (TMS-line), where the latter was the focus of this thesis project. Since the transition is already put in motion, there is an urgent need for the establishment of a production ramp-down strategy stretching until the complete transition. Therefore, this project was initiated to develop an optimal strategy of the production ramp-down with regard to interconnected projects and functions, as well as to the factors of economics, efficiency, ergonomics, and quality. The project also aimed to establish an ideal project progression regarding the management and implementation of the strategy. Considering that the TMS-line involves 59 workstations, more than 200 personnel daily, 10 engine types with unique variants, different technical systems, and must align with multiple operational functions, a comprehensive and considered strategy was essential. An additional objective was to reduce the gap in research between production ramp-up and production ramp-down. Although, the interest of production ramp-up has increased considerably in the last two decades, that of production ramp-down still remains widely neglected, despite their similar importance. Hence, the project aimed not only to contribute to Scania, but also to contribute with empirical data to future research in production ramp-down. Altogether, the reduction in the research gap can contribute to more sustainable production systems. To achieve the project objective and aims, a substantial literature review was conducted and a wide array of scientific methods were used. The literature review established a basis for the project, and brought theories from multiple languages and standpoints together to culminate in a comprehensive understanding of production ramp-down. The scientific methods were used to gather empirical data and to design the strategy. In addition, relevant expertise was incorporated throughout the project by a continuous cooperation with Scania employees of different roles and specialisations. The project also followed Scania’s change process to facilitate the realisation of the strategy. In total, three distinctive strategy concepts were generated and evaluated, called Alpha, Beta, and Gamma. Then, after a systematic evaluation process, a combination of Alpha and Gamma was designed in detail to form the final strategy. The strategy can be described as a stepwise capacity reduction. The first step is the planning and preparation for the necessary competence shift, organisational changes, and technical solutions. In the second step, a new takt and work standard corresponding to 50% capacity is implemented. Also, a decision regarding the final production years is made to either offshore production, change layout, or continue without change. The third step involves major structural changes in the form of a new organisational structure and the implementation of a technical solution for a permanent 50% capacity reduction. Similarly, in the fourth step, the technical solution is adjusted and a new work standard is implemented to correspond to a 33% capacity need. The fifth step regards the phase-out of the TMS-line, which completes the transition between DL and DW. Finally, the sixth step includes the revitalisation of the freed-up operational area and recycling of production equipment and materials. Altogether, the strategy ensures an optimal production ramp-down of the TMS-line with regard to interconnected projects, functions, and factors. To ensure the success of the strategy, recommendations in management and implementation of the strategy were established based on research and empirical findings. The result is an optimal strategy that fulfils the objective and aims, and contributes with new empirical findings and recommendations for future research in production ramp-down and connected research fields. / Med bakgrunden av det ökande kraven och konkurrensen i fordonsindustrin att snabbt introducera nya produkter till marknaden, har ledning av produktionsupprampningar och produktionsnedrampningar blivit en ny avgörande konkurrensfaktor. För att lyckas med denna ledning krävs en välutvecklad strategi. För Scania motormontering pågår denna nya utmaning i formen av en nedrampning av den gamla monteringslinan (DL) och samtida upprampning av den nya monteringslinan (DW). Detta genomförs för att leverera den nya och mer hållbara motorplattformen Super. DL består av en grundmontering och en slutmontering (TMS-line), där den sistnämnda utgör fokus i detta examensarbete. Eftersom övergången redan är i gång finns det ett brådskande behov för utformningen av en produktionsnedrampningsstrategi som sträcker sig fram till den fullständiga övergången. Därför initierades detta projekt för att utveckla en optimal strategi för produktionsnedrampningen med hänsyn till sammankopplade projekt och funktioner, likväl till ekonomi, effektivitet, ergonomi och kvalitet. Projektet ämnade även till att utforma en idealisk projektprogression gällande styrning och implementering av strategin. Då TMS-line involverar 59 arbetsstationer, över 200 operatörer dagligen, 10 motortyper med unika varianter, olika tekniska system, och måste anpassas till flera operationella funktioner, krävdes en heltäckande och genomtänkt strategi. Ett ytterligare mål var att minska forskningsgapet mellan produktionsupprampning och produktionsnedrampning. Även om intresset för produktionsupprampning har ökat avsevärt de senaste två decennierna, frånses produktionsnedrampning fortfarande trots deras liknande betydelse. Därför ämnade projektet inte bara till att bidra till Scania, men också till att bidra med empirisk data till framtida forskning inom produktionsnedrampning. Sammantaget kan minskningen av forskningsgapet bidra till mer hållbara produktionssystem. För att uppnå projektets syfte och mål utfördes en omfattande litteraturstudie och olika vetenskapliga metoder användes. Litteraturstudien upprättade en grund för projektet, och sammanförde teorier från flera språk och perspektiv för att ge en heltäckande förståelse av produktionsnedrampning. De vetenskapliga metoderna användes till att samla empirisk data och designa strategin. Dessutom integrerades relevant expertis genom hela projektet genom ett kontinuerligt samarbete med anställda på Scania med olika roller och specialiseringar. Projektet följde även Scanias förändringsprocess för att underlätta implementeringen av strategin.  Totalt skapades och utvärderades tre distinkta strategikoncept: Alfa, Beta, och Gamma. Efter en systematisk utvärderingsprocess designades en kombination av Alfa och Gamma i detalj till att utforma den slutliga strategin. Strategin kan beskrivas som en stegvis kapacitetsreducering. Det första steget utgör planeringen och förberedelsen gällande kompetensskifte, organisatoriska förändringar, och tekniska lösningar. I det andra steget implementeras en ny takt och arbetsstandard motsvarande 50 % kapacitet. Dessutom görs ett beslut gällande de sista produktionsåren att antingen flytta produktion utomlands, ändra layout, eller fortsätta utan förändring. Det tredje steget involverar stora strukturella förändringar i formen av en ny organisatorisk struktur och implementeringen av en teknisk lösning för en permanent kapacitetreducering på 50 %. I det fjärde steget justeras den tekniska lösningen och en ny arbetsstandard implementeras motsvarande ett kapacitetsbehov på 33 %. Det femte steget berör utfasningen av TMS-line vilket slutför övergången mellan DL och DW. Slutligen inkluderar det sjätte steget vitaliseringen av den frigjorda operationella ytan och återvinningen av produktionsutrustning och material. Sammantaget säkerställer strategin en optimal produktionsnedrampning av TMS-line med hänsyn till sammankopplade projekt, funktioner och faktorer. För att säkerställa strategins framgång upprättades rekommendationer i styrning och implementering baserat på forskning och empiriska fynd. Resultatet är en optimal strategi som uppfyller syfte och mål, samt bidrar med nya empiriska fynd och rekommendationer till framtida forskning i produktionsnedrampning och relaterade forskningsfält.

With the rise of smart manufacturing technologies and a shift towards a new industrial revolution, brings forth many new challenges, one of which is how to adapt and integrate these technologies into existing assembly lines. Scania CV AB has joined this race and, with the help of smart manufacturing solutions, works on increasing efficiency amongst its assembly lines. This thesis is aimed at creating concept designs using different smart manufacturing technologies in the assembly line of a pedal car, to evaluate and adapt the concept suited for a real assembly line. The thesis starts with studying the different smart manufacturing technologies to better understand them and the scientific methods used. This follows up with the methodology where several scientific methods such as morphological matrix and weight based decision making matrix are used to generate and evaluate different concept designs. This is followed by a qualitative analysis that helps in selecting the concept design that best suits the needs of the assembly line under consideration. The different concepts are visualized and the evaluation based on different parameters are discussed. This thesis lays a foundation to realize that an aggregate of an optimized process plan, a continuous improvement strategy and the right use of smart manufacturing technologies contributes to the productivity of the assembly line in the long run. / Med en ökning av smarta tillverkningsteknologier och ett skift mot en ny industriell revolution, kommer nya utmaningar. Av dessa utmaningar ifrågasätts hur man anpassar och kombinerar dessa olika teknologier gentemot existerande monteringslinjer. Scania CV AB har tagit del i denna resa och, med hjälp av smarta tillverkningslösningar, jobbar ständigt mot att effektivisera sina monteringslinjer. Detta examensarbete fokuserar på att använda olika och smarta tillverkningsteknologier i en monteringslina för tillverkning av en trampbil. Detta görs genom att evaluera och anpassa olika koncept som är lämpade för en verklig monteringslina. Examensarbetet börjar med en undersökning av nuläget för att få en bättre uppfattning om smarta tillverkningsteknologier samt de vetenskapliga metoder som används. Även här så undersöks referensprodukten - trampbil samt de olika programvarorna AviX, ExtendSim och LayCAD. Genom att ha satt tydliga arbetsmetoder och följt upp mot dessa så diskuterar och hänvisar nästa kapitel resultaten. Resultaten visar hur olika koncept har tagits fram samt vilka teknologier som går ihop med dessa. Fördelar, nackdelar och risker hos respektive teknologi har benämnts. Ett systematiskt arbetssätt har tagits fram mot hur man anpassar konceptet för monteringslinan av en trampbil till en verklig monteringslina, samt hur man har jobbat runt de restriktioner som uppkommit. Examensarbetet slutar med ett kapitel där slutsatserna, på en överskådlig nivå, tas fram. Hur dessa teknologier har kombinerats och evaluerats, samt att koncepterna som har tagits fram har lagt en grund för framtida projekt att följa upp emot.

Volvo Trucks is the second-largest heavy-duty truck provider in the world. As of now they are working towards fossil free transport solutions. This comes with a fast development pace and an increasing need of being able to verify new and complex assembly processes to ensure an integration of the production of new truck models together with the current vehicles that are being produced.  This project is a master thesis that focuses on improving the quality and verification capabilities of the Pilot Plant at the Volvo Tuve site. The goal of the project is to design and develop a modular transport solution that can be used to move truck chassis at a predefined speed to be able to simulate and perform assembly tasks with the same parameters in the test environment as in the factory process along the driven line. The design was developed using the product development process described by Ulrich et al., 2020, with slight modification. The resulting design is able to move the truck chassis at the requested predefined speeds that are possible on the driven line in the factory. This solution gives Volvo the ability to perform simulations of specific and critical assembly steps, potentially resulting in fewer failures during production ramp-up of their new truck models.  Calculations were made to in order to verify the strength and functionality of the design.