Tillverkningsföretag med lågvolymsproduktion måste hitta lösningar för att förbättra effektiviteten som inte kräver stora investeringar för att göra verksamheten lönsam. I denna studie undersöks hur effektiviteten kan förbättras för plåtdetaljer genom förändring av tillverkningsmetoder samt omkonstruktion med avseende på produktion. Genom undersökning av ett specifikt fall behandlar studien hur konventionella tillverkningsmetoder såsom svetsning och kantpressning kan ersättas med plåtformningsmetoder. Metoderna tryckformning, flexforming och djuppressning har studerats och utvärderats. Studien visar att flexformning och sammanfogning med skruvförband resulterar i kortare tillverkningstid, lägre tillverkningskostnader och lägre kompetens samtidigt som god kvalitet erhålls. Däremot kan ersättningen av kantpressning medföra en kostnadsökning till förmån för arbetsmiljön.

For a company to be competitive today, one way is to create a natural feedback loop from the production department to the design department with information regarding the production systems ability to deliver a finished component. The purpose with this feedback loop is to create respect for tolerances and to more design for manufacturing and assembly. The studied company in this thesis work developed a quality program to reach a spiral of continuous improvements to reduce cost of poor quality (CoPQ) and to reach an improved quality level (PPM). The object of this work was to test and improve the quality program called The Zero Tolerance Program. Delimitations were made when the work was started and ongoing which led to that the impact on PPM could not be studied. The connection to CoPQ was difficult to obtain and could only be proved theoretically, not practically, due to the short timetable. During the short amount of time the right root cause could not be found. The thesis work findings came to a number of identified Measurable Success Criteria and requirements which must be in place for the further progress of The Zero Tolerance Program. / PREPARE

Microelectronic systems packaging involves layout dimensions of the order of microns. During manufacturing, process variations will cause parameters to deviate from their nominal values. As a result, the manufactured circuit may no longer meet the specifications it is designed to satisfy. When producing high volume of electronics, assembly yield becomes very important. This is where tolerance margins of the design parameters play an important role. This means that the performance specifications should be satisfied if the process variations are within the given tolerance margin of design parameters. Research has been done on circuit level design for manufacturability methods. The main objective of the research is to study the layout level DFM methods for signal integrity issues and embedded Rf passive components and use design centering methodology to improve the output yield value. In this dissertation, emphasis is also laid on taking care of the regression error while calculating the yield value. With the developed method, the number of design iteration cycles to maximize yield is significantly reduced.

Nowadays, there are more and more regulations regarding the emissions of greenhouse gases. The automotive sector is directly affected by new standards enacted by the National Highway Traffic Safety Administration (NHTSA) in America and by European regulations in Europe that are forcing car manufacturers to produce more efficient cars. Different ways exist to increase the efficiency of a car and thus reduce the CO2 emissions. One known strategy to improve fuel economy in vehicles is by weight reduction. Consequently, car manufacturers are seeking out new companies that can supply them with lighter car components. Here is where VA Automotive enters the picture, as a car seat manufacturer that is willing to improve their product by reducing the weight of its various components. This study deals with the development of a new recliner design that demonstrates improvements in terms of weight, size and performance compared to the current solution used at VA Automotive. A common product development methodology has been developed to reach the final recliner design which went through the following steps. First of all, a benchmarking technique was adopted to gather as much data as possible from the competitors’ products. Then, a list of target values for the product specifications was defined as a guideline for the development of the product. The next step was to generate several concepts of recliner’s mechanism that were suitable to improve the design from VA Automotive. After that, a Pugh decision matrix was used to select the best alternative between the concepts generated previously. The optimal concept was further developed by generating four design alternatives that were analyzed in terms of manufacturing, assembly, weight and size by using the Lucas DFMA method. Finally some simulations were run for one of the designs in order to check the structural performance of the mechanism and prove this way that the new recliner design meets the requirements. When comparing the new design alternatives with the design from VA Automotive, it was noticed that all the new designs except one presented a lower manufacturing cost index. Moreover, for all of the alternatives of the new recliner design, the weight was reduced by more than 56% compared to the recliner used at VA Automotive. Finally, by means of FEM simulations it was demonstrated that by choosing the right material the new recliner design was able to meet the structural requirements.

Welded structures susceptible to weld deformations require sequent processing to allow for mounting of precision components. This thesis includes a case study of the rear axle mount on a Volvo L220 wheel loader. A product development process was deployed in order to explore and evaluate alternative mounting methods such that manufacturing cost due to sequent processing could be decreased. Analysis of the frame variations showed any new concepts has to accommodate variations of up to $\delta z=-1.24\pm3.5$ mm. The product development process found two potential concept philosophies; transferring concepts which improves upon the current concept by transferring the processing away from the frame onto smaller components that are cheaper to process, and absorbing concepts that avoids sequent processing by absorbing the frame variations altogether. The transferring concept "Custom Plate" was selected for further development. The concept is based on the principals of reverse engineering by manufacturing a custom plate from a 3D surface map of the deformed mounting surface, placed between the frame and rear axle bridge, matching the surface geometry of both entities. The concept showed no apparent critical strength issues when simulated in CATIA V5. However, the economical gain of the concept is slim and depends heavily what spaces can be allocated for additional processing machinery. Suggestions for further development of the concept are given along with a discussion of improvements outside of the system boundary of the project, such as simulation of welds and welding sequence, and collection, storing, analysis, and visualisation of data.

In laboratory work and working with Biotage’s Selekt Enkel chromatography system, it is common that operators are exposed to harmful and bad-smelling solvents gases. These are common issues that Biotage wants the students to solve. For this thesis work, the mission and task is to propose the best possible design of a Fume Cover that can remove or at least reduce those certain issues. To understand and gain the necessary knowledge, different data-gathering methods like workshops with staff and an extensive literature study of solvents and materials helped to establish a good design framework. Three concepts were built as 3D – models. The concept of Pugh’s iterative improvement method was used to produce an even better concept than the previous three. The chosen concept was iteratively improved for manufacturing and tested in an airflow experiment with carbon dioxide ice determining the optimal design. The conclusion is that it is possible to design a fume cover to reduce the solvent gas exposure, but further testing with light solvent gases and redesign will be required.

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Kundanpassning är ett ökande problem för tillverkare och det gäller även för Zetterbergs därproblemet nu är att konstruera lastbilsprodukter som ska passa till alla kunder vars lastbils-fabrikat varierar. Syftet med studien var att utveckla CAD-modeller för en ljusanordning medbred kundanpassning, lågt komponentantal och mindre skador vid tillämpning.För att utföra arbetet användes teori inom DFM (Design For Manufacturing), regelverk ochde tillverkningsmetoder som fanns till godo hos företaget. Datainsamlingen bestod av inter-vjuer, litteraturstudier och observationer. Arbetet följde en generell produktutvecklingspro-cess som började med konceptgenerering. Valet av vinnande koncept för vidareutvecklingbestämdes med Pughs matris. Vidareutvecklingen utfördes i Solidworks där även FEM-ana-lyser och topologioptimerings-analyser utfördes i syfte att förbättra konstruktionerna utanatt förlora hållfasthet och vibrationskänslighet.Resultatet blev två CAD-ritade ljusanordningar vars vikt var lägre än den nuvarande anord-ningen. Distansen mellan skadepunkter och lastbilens ände ökade jämfört med originalet. Enav konstruktionerna hade färre komponenter än originalet. De resulterande ljusanordning-arna visade goda egenskaper, men det finns rum för korrigeringar, som delvis missades imån av tidsbrist. Vidare var de utförda FEM-analyser och topologioptimeringar förenklingarav verkligheten och därför är det svårt att bedöma om dessa adekvat representerar praktiskanvändbarhet utan verkliga tester. Det är därför av framtida intresse att tillverka ljusanord-ningarna i resultatet och testa prestandan i verkliga scenarion, men också för att identifieraeventuella tillverkning och monteringsproblem som omedvetet har negligerats. / Product-customization is a growing problem for manufacturers which is also true for Zetterbergs where the problem currently is to construct lorry products that fit the customers varying lorry-types. The purpose of the study is to develop CAD-models for a back light ordinance with broad customer adaptability, lower assembly component quantity and less damage occurrence during use of the product. To complete the task, design theory including DFM (Design For Manufacturing), manufacturing methods available at the company and regulatory limitations were researched. The data collection consisted of interviews, literature studies and observations. The work followed a general product development process that began with concept generation. Choosing the winning concepts for further development was done through Pugh’s decision matrix. Further development was conducted in SolidWorks where FEM analyses and topology optimizations also were conducted with the purpose of improving the constructions without losing strength and vibratory properties. The result of the study were two light ordinances with their respective construction drawings. The weight of the two ordinances were lower than the original. The distance between damage-points and the endpoint of the lorries both increased. One construction had lower component quantity than the original. Both constructions showed good characteristics. There is room for improvement however as some aspects may have been missed due to time restrictions. Furthermore, the FEM and topology analyses were simplifications of reality. It would be valuable to create real prototypes from the result and conduct tests in more realistic scenarios and simultaneously identify subconsciously neglected manufacturing and assembly issues.

With a more global market, manufacturing companies have to increase their focus on cost management to stay competitive. With new technologies available, new methods of evaluating concepts and ideas arise. Among these are simulation tools. Thus, the purpose of this study is to investigate how simulation tools can be integrated into the product development process to improve target costing. To achieve this purpose, a case study was conducted at a large manufacturing company, where a simulation tool was used. It was found that cost and manufacturing simulation tools can be used for target costing, negotiation with suppliers, as well as a helpful tool for design methods such as design for manufacturing and design to cost. Furthermore, cross-functional teams and good collaboration are a postulate for successful implementation and utilization of simulation tools in the product development process. The proposition is therefore that large manufacturing companies with advantage should implement cost and manufacturing simulation tools into their product development process to improve target costing. / Med en mer global marknad måste tillverkningsföretag öka sitt fokus på kostnadshantering för att förbli konkurrenskraftiga. Med ny teknik tillgänglig uppstår nya metoder för att utvärdera koncept och idéer. Bland dessa finns simuleringsverktyg. Syftet med denna studie är därför att undersöka hur simuleringsverktyg kan integreras i produktutvecklingsprocessen för att förbättra arbetet med målkostnader. För att uppnå detta syfte genomfördes en fallstudie på ett stort tillverkningsföretag där ett simuleringsverktyg användes. Det upptäcktes att kostnads- och tillverkningssimuleringsverktyg kan användas för målkostnadsberäkning, förhandlingar med leverantörer, samt att det kan vara ett användbart verktyg för designmetoder såsom design for manufacturing och design to cost. Vidare är tvärfunktionella team och gott samarbete en förutsättning för en framgångsrik implementering och användning av simuleringsverktyg i produktutvecklingsprocessen. Därför bör stora tillverkningsföretag med fördel implementera kostnads- och tillverkningssimuleringsverktyg i sin produktutvecklingsprocess för att förbättraarbetet med målkostnader.