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The master thesis at Sandvik Additive Manufacturing Division, Sandviken, aims at three things. The first step is to estimate the cost of a Binder jet Additive Manufacturing method and identify the key cost drivers in the manufacturing process, since cost estimation can help the organisation to understand the cost factors that are affecting the product's price. Also assisting the sales team to create a foundation to price quote their customers and raise profit margins. Hence the first part of the thesis emphasizes creating an easy-to-use template for the organization's production and sales teams. The second part of the thesis is to provide an Excel sheet that is simple to use for computing the yearly budgets so that it serves as a technique for forecasting impending outflows within the company. Hence, a quarterly and yearly budgeting template that the sales and production team can use at Sandvik AM division is designed. The final objective of this thesis is to establish the Binder Jet machine's Overall Equipment Efficiency key performance indicator. This is done by taking into account availability, performance, and quality. These three factors are tracked from the additive manufacturing machines using an automated OEE Key Performance Indicator calculator that collects data from the build reports into Excel using the power query tool. / Examensarbetet vid Sandvik Additive Manufacturing Division, Sandviken, syftar till tre saker. Det första steget är att uppskatta kostnaden för en Binder jet Additive Manufacturing-metod och identifiera de viktigaste kostnadsdrivkrafterna i tillverkningsprocessen, eftersom kostnadsuppskattning kan hjälpa organisationen att förstå de kostnadsfaktorer som påverkar produktens pris. Hjälper även säljteamet att skapa en grund för att prissätta sina kunder och höja vinstmarginalerna. Därför fokuserar den första delen av avhandlingen på att skapa en lättanvänd mall för organisationens produktions- och säljteam. Den andra delen av uppsatsen är att tillhandahålla ett Excel-ark som är enkelt att använda för att beräkna den årliga budgeten så att det fungerar som en teknik för att prognostisera förestående utflöden inom företaget. Därför utformas en mall för kvartalsvis och årlig budgetering som sälj- och produktionsteamet kan använda på Sandvik AM-divisionen. Det slutliga målet med denna avhandling är att fastställa Binder Jet-maskinens övergripande utrustningseffektivitets nyckelprestandaindikator. Detta görs genom att ta hänsyn till tillgänglighet, prestanda och kvalitet. Dessa tre faktorer spåras från de additiva tillverkningsmaskinerna med hjälp av en automatiserad OEE Key Performance Indicator-kalkylator som samlar in data från byggrapporterna till Excel med hjälp av kraftfrågeverktyget.

AGES är ett företag som pressgjuter produkter i aluminium med olika legeringar. De producerar främst till fordons- och verkstadsindustrin. De har i dagsläget låg total utrustningseffektivitet på två av sina maskiner och vill få reda på varför. De största tidsförlusterna är ställtiderna samt att operatörerna inte märker att maskinstopp har skett.    Målet med examensarbetet var att identifiera och reducera slöseri i produktionsprocessen hos AGES och skapa en grund för framtida arbete med SMED och Lean Production.     Genom olika mätningar kunde olika analyser utföras såsom värdeflödesanalys och OEE-analys. Analyserna resulterade i ett antal förbättringsförslag där vissa av dem planeras att implementeras. Vissa hamnade under utvärdering och vissa hamnade som framtida förbättringar. Studien har också bidragit till en ökad förståelse för varför maskinstopp sker och vilka åtgärder som bör vidtas. Ledningen på AGES är positiva till resultatet av studien och förbättringsförslagen. Inom SMED har det resulterat i en plan till hur verktygsbytet kan gå till för att minska ställtiderna samt hur mycket tid som kan besparas vid implementering. / AGES is a company that die-cast aluminum products with various alloys. They mainly produce for the automotive and engineering industries. Currently they have a low total equipment efficiency on two of their machines and they want to find out why. The biggest time losses are the set-up times and that the operators are not noticing when a machine stop has occurred.   The aim of the project was to identify and reduce waste in the production process at AGES and create a basis for future work with SMED and Lean Production.    Through different measurements, different analyzes could be performed such as value flow analysis and OEE-analysis. The analyzes resulted in several improvement proposals, some of which are planned to be implemented. Some will be evaluated and will be implemented as future improvements. The study has also led to an understanding of why machine stops occur and what measures should be taken.    The management at AGES is positive to the results of the study and the improvement proposals. Within SMED, it resulted in a plan for how the tool change can be done to reduce set-up times and how much time can be saved when implemented.

The usage of information technology (IT) systems has become an integral part of assembly manufacturing. Supervisory control and data acquisition (SCADA) systems are widely used in order to control production cycles and monitor equipment such as conveyor belts. Other common IT systems are related to logistics, data analysis, or organizing of incoming and outgoing orders. In this thesis we create a model for the IT systems at the fuel pump and fuel injector manufacturer Scania XPI. One model is developed for the current state of the IT systems at Scania XPI, and one model is developed detailing the future state. The current state model consists of charts showing where in the production process that data is transmitted between which IT systems. This thesis utilizes the current state model in order to suggest improvements to the IT systems. These improvements are detailed in the model for the future state of IT systems at Scania XPI. Overall equipment efficiency (OEE) is a measurement of the performance of an industrial operation based on the percentage of up time running at full capacity compared to the available run time. Measurement of OEE requires that only downtimeduetointernal circumstances within the operation is taken into account, and that any potential quality deviations due to the operation are accounted for. Taking into account the variability of manufacturing processes, this thesis proposes solutions to issues in data processing required to measure the efficiency of operations in assembly manufacturing, such as identifying if process breakdowns are caused by external factors. The proposed solution is a system called "Process data analysis system" (PDAS), which uses the recorded machine statuses throughout operation in order to calculate process downtime and OEE. PDAS was implemented using the incremental waterfall model as a software development methodology. PDAS was evaluated by conducting four groups of experiments and a comparison to the PUS (processuppföljnings system) at Scania XPI. Automatically classifying downtime events as planned or unplanned allows PDAS to give an accurate view on the efficiency of the assembly production. The software can be used at Scania XPI and it’s functionality has been verified on assembly production running in ordinary conditions. We show that software can be developed to process industrial data in order to measure assembly line efficiency. Eventually, design and implementation of a downtime management system for assembly production is achieved as a final product of this thesis. / Användningen av informationsteknik (IT) system har blivit en viktig del av monteringstillverknings industrin. Supervisory control and data acquisition (SCADA) system är ofta implementerade i syfte att kontrollera produktionens takt och för att övervaka eller styra produktionens utrustning. Andra vanliga IT-system är relaterade till logistik, data analys, eller hantering av ingående och utgående beställningar. I detta examensarbete skapar vi en modell för IT-systemen på dieselpump och dieselinjektor tillverkaren Scania XPI. Denna modell visar både hur IT-systemen fungerar idag och hur de kan förbättras. Current state modellen består av diagram som visar var i produktionsprocessen som data skickas mellan IT-systemen. Vi använder oss av current state modellen i syfte att föreslå förbättringar till IT-systemen. Dessa förbättringar beskrivs i en modell för future stateäv IT-systemen hos Scania XPI. Overall equipment efficiency (OEE) är ett mått på prestandan på effektiviteten av industriell verksamhet baserat på procentandelen av drifttiden utan kvalitets avvikelser utan stopp jämfört med den totala drifttiden. Mätning av OEE kräver att driftstopp på grund av externa omständigheter ej tillräknas stopp tiden, och att kvalitets avvikelser kan mätas. Detta examensarbete föreslår lösningar på problem inom databehandling som krävs för att mäta produktionens effektivitet vid monteringstillverkning, exempelvis att identifiera om driftstopp som orsakas av externa omständigheter. Lösningen som presenteras är utveckling av Process Data Analysis System"(PDAS), som använder sig av automatiskt rapporterad maskinstatusdata för att beräkna stopp tid och OEE. PDAS implementerades med "incremental waterfall modelsom metodologi för mjukvaruutveckling. PDAS utvärderades genom att genomföra fyra grupper av experiment och med hjälp av en jämförelse med PUS (processuppföljnings system) hos Scania XPI. Genom att automatiskt klassificera planerad och oplanerad stopp tid ger PDAS en mer ackurat bild av effektiviteten för monterings produktionen. Mjukvaran kan användas av Scania XPI och funktionen av PDAS har verifierats för monteringstillverkningen under vanliga produktionsomständigheter. Vi visar att mjukvaran kan användas för att bearbeta industriell data i syfte att mäta effektiviteten av monterings tillverkningen. Slutligen uppnås design och implementation av ett system för stopptids hantering för monterings produktion som en produkt av denna uppsats.

Syftet med studien är att få en förståelse för hur utrustningseffektiviteten kan mätas i ett producerande företag. Vår studie utförs på ett företag i Alvesta som heter Gnutti Powertrain AB som bland annat tillverkar precisionskomponenter till motorer. Genom att vi skapar en analysmodell utifrån studerade teorier beskrivs ett systematiskt tillvägagångssätt som slutligen ska leda till att syftet uppnås. Utifrån analysmodellen studeras och beskrivs först Gnutti Powertrain AB´s nuvarande tillvägagångssätt för att sedan jämföras och analyseras gentemot de studerade teorierna. Med hjälp av analysmodellen struktureras också vår studie på företaget och vårt utförande och resultat utifrån detta kommer sedan att presenteras. Analysmodellen nämner att en processkartläggning först ska göras. I processkartläggningen väljs först en specifik process ut, vilken i vårt fall blev produktionsprocessen för en rulle av stål. Därefter lokaliserar, dokumenterar och beskriver vi alla de aktiviteter som bygger upp processen. Enligt nästa steg i analysmodellen görs en värdeflödeskarta som behandlar alla de aktiviteter som tillför värde till produkten och nämner data som är viktig att samla in för att kunna göra beräkningar och utvärderingar. Denna data samlades in och presenterades i värdeflödeskartan. Värdeflödeskartan kan också underlätta identifieringen av de mest kritiska aktiviteterna. I vår studie var de kritiska aktiviteterna redan utvalda på förhand som fyra olika maskiner i flödet då de vid senare tillfälle eventuellt ska byggas samman till en linje. Som sista steg i analysmodellen görs beräkningar på utrustningseffektiviteten med hjälp av TAK. En del av datan från värdeflödeskartan kunde användas för att göra TAKberäkningarna. Resten av den data som krävdes vid beräkningarna samlades in genom intervjuer och möten med personal eller genom egna mätningar i produktionen. TAK-värdet varierar på de fyra maskinerna och även fyra olika beräkningar görs på varje maskin där olika data från störningar används. De olika värdena varierar mellan cirka 61% till 91%. Utifrån beräkningarna görs jämförelser om hur olika störningar påverkar TAK-värdet där även varje störning beskrivs. Vid utförandet och beräkningarna uppkom flera olika tankar och funderingar på nuläget hos Gnutti Powertrain AB. Något som tydligt framkom var att de rapporteringar som varje operatör gör i affärssystemet inte alltid är korrekta. Då TAK III beräkningarna helt bygger på rapporterna medför detta att både vårt och Gnutti Powertrain AB´s TAK-värden kan bli felaktiga. Resultatet och diskussionen kring resultatet ledde till att vi kunde dra vissa slutsatser för att kunna komma med rekommendationer till företaget. Det konstateras att Gnutti Powertrain AB bör använda nuvarande mätmetod för TAK men fokusera på att förbättra deras rapporteringar i affärssystemet.

The main subject of the master's thesis "Study of machines efficiency in manufacturing process" is the lean processes in the organization. The introductory section describes the theoretical grounds and methods of lean manufacturing. The main section consists of the analysis of selected manufacturing processes, including the implementation of two proposed solutions. The result of work is the elimination of certain types of waste during the production. Another contribution is improving of packaging processes at distribution to the customer.

The research topic is: Tools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles. This research has specific reference to the SASOL Prillan plant based in SASOL, Sasolburg. The purpose of this research is to identify tools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles. These tools must be aimed to increase the proactive work capacity index, Figure 3, and to identify and/or develop tools that can be used by the engineering team of this explosives manufacturing plant to increase equipment reliability and performance. In this research assets include people. The meaning and application of asset management principles were researched and the tools needed to combine existing efforts and future needs are discussed. The human element to ensure the successful implementation of an asset management culture was researched and attributes of leaders and a change model is presented. This research was done into the wider engineering management discipline and not only maintenance. The method used to gather data was by means of interviews of a sample group within this organization. As this manufacturing unit makes use of subject matter experts, these support functions and plant personnel that were not interviewed, were issued with questionnaires to ensure that the sample group is a fair representation of the total manufacturing facility. To obtain a holistic view of potential shortcomings within the current maintenance strategy, all disciplines and levels within this operation were interviewed and commonalities of various asset management models were determined and used to define existing problem areas. This data was used to determine statistical correlations. The case study presented in Chapter 1 indicates that there is a case for change that can improve the proactive work capacity index of the engineering team. The results of this research confirm that there is in fact a real requirement to increase spares accuracy, improve on technical training as well as a need to establish visual performance indicators (dashboard) to measure overall equipment efficiency with the goal toTools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles increase equipment reliability and performance. The technical training referred to in this research reflects on training of people on equipment after investment in new technology. The current spares holding strategy is lacking equipment description accuracy. Furthermore, it is recommended that the implementation of career paths and development plans for individuals must be developed to create an environment of learning. The use of user status information captured on the computerized maintenance management system (SAP R/3) can add to the management of works orders and indicate where the focus must be to complete overdue work orders. Open work orders should be used to manage expenditure, to measure planning efficiency and to manage the cash flow of the business. The use of overall equipment efficiency and engineering efficiency measures is recommended and must be visually displayed on a “dashboard”. It was recommended that the engineering and operations personnel of this manufacturing plant be trained in asset management principles and that balanced scorecards are developed to ensure that the strategies of the various departments are aligned with the business strategy. Diagram 1 best illustrates the thinking and process flow of this research. The flow diagram shows five distinct stages and the appropriate objectives and/ or elements that were considered. The dissertation is also structured in this manner. All abbreviations, acronyms and definitions used in this document were listed in APPENDIX B / Thesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2009.

The research topic is: Tools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles. This research has specific reference to the SASOL Prillan plant based in SASOL, Sasolburg. The purpose of this research is to identify tools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles. These tools must be aimed to increase the proactive work capacity index, Figure 3, and to identify and/or develop tools that can be used by the engineering team of this explosives manufacturing plant to increase equipment reliability and performance. In this research assets include people. The meaning and application of asset management principles were researched and the tools needed to combine existing efforts and future needs are discussed. The human element to ensure the successful implementation of an asset management culture was researched and attributes of leaders and a change model is presented. This research was done into the wider engineering management discipline and not only maintenance. The method used to gather data was by means of interviews of a sample group within this organization. As this manufacturing unit makes use of subject matter experts, these support functions and plant personnel that were not interviewed, were issued with questionnaires to ensure that the sample group is a fair representation of the total manufacturing facility. To obtain a holistic view of potential shortcomings within the current maintenance strategy, all disciplines and levels within this operation were interviewed and commonalities of various asset management models were determined and used to define existing problem areas. This data was used to determine statistical correlations. The case study presented in Chapter 1 indicates that there is a case for change that can improve the proactive work capacity index of the engineering team. The results of this research confirm that there is in fact a real requirement to increase spares accuracy, improve on technical training as well as a need to establish visual performance indicators (dashboard) to measure overall equipment efficiency with the goal toTools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles increase equipment reliability and performance. The technical training referred to in this research reflects on training of people on equipment after investment in new technology. The current spares holding strategy is lacking equipment description accuracy. Furthermore, it is recommended that the implementation of career paths and development plans for individuals must be developed to create an environment of learning. The use of user status information captured on the computerized maintenance management system (SAP R/3) can add to the management of works orders and indicate where the focus must be to complete overdue work orders. Open work orders should be used to manage expenditure, to measure planning efficiency and to manage the cash flow of the business. The use of overall equipment efficiency and engineering efficiency measures is recommended and must be visually displayed on a “dashboard”. It was recommended that the engineering and operations personnel of this manufacturing plant be trained in asset management principles and that balanced scorecards are developed to ensure that the strategies of the various departments are aligned with the business strategy. Diagram 1 best illustrates the thinking and process flow of this research. The flow diagram shows five distinct stages and the appropriate objectives and/ or elements that were considered. The dissertation is also structured in this manner. All abbreviations, acronyms and definitions used in this document were listed in APPENDIX B / Thesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2009.

El presente trabajo plantea una simulación ante el problema de imprevistos a lo largo de la línea de los ductos que transporta el gas de Camisea que causa pérdidas económicas a la empresa mantenedora “TECHINT”, a la empresa concesionaria del transporte “TGP” y al Estado Peruano. La metodología seguida ha sido la revisión del número de ocurrencias recopiladas en un horizonte de tiempo de 2 años, esto fue comparado con una simulación en el sistema Arena bajo un modelo de mejora basada en 6 pilares del TPM y OEE, Los resultados con la mejora propuesta, evaluada en un año, arrojan un aumento del indicador con una disponibilidad promedio de 74,04%, un rendimiento promedio de 85,8% y una calidad promedio 50% de los equipos, obteniendo un indicador OEE promedio del 83,01%, el cual se genera como resultado del producto de los valores mensuales de la disponibilidad, rendimiento y calidad / The present work proposes a simulation of the problem of unforeseen events along the pipeline line that transports Camisea gas, which causes economic losses to the maintenance company "TECHINT", to the transport concessionaire "TGP" and to the Peruvian State. The methodology followed has been the review of the number of occurrences collected in a time horizon of 2 years, this was compared with a simulation in the Arena system under an improvement model based on 6 pillars of TPM and OEE. The results with the proposed improvement, evaluated in one year, show an increase of the indicator with an average availability of 74.04%, an average performance of 85.8% and an average quality 50% of the equipment, obtaining an average OEE indicator of 83.01%, which is generated as a result of the product of the monthly values of availability, performance and quality. / Trabajo de Suficiencia Profesional

El presente trabajo plantea una simulación ante el problema de imprevistos a lo largo de la línea de los ductos que transporta el gas de Camisea que causa pérdidas económicas a la empresa mantenedora “TECHINT”, a la empresa concesionaria del transporte “TGP” y al Estado Peruano. La metodología seguida ha sido la revisión del número de ocurrencias recopiladas en un horizonte de tiempo de 2 años, esto fue comparado con una simulación en el sistema Arena bajo un modelo de mejora basada en 6 pilares del TPM y OEE, Los resultados con la mejora propuesta, evaluada en un año, arrojan un aumento del indicador con una disponibilidad promedio de 74,04%, un rendimiento promedio de 85,8% y una calidad promedio 50% de los equipos, obteniendo un indicador OEE promedio del 83,01%, el cual se genera como resultado del producto de los valores mensuales de la disponibilidad, rendimiento y calidad. / The present work proposes a simulation of the problem of unforeseen events along the pipeline line that transports Camisea gas, which causes economic losses to the maintenance company "TECHINT", to the transport concessionaire "TGP" and to the Peruvian State. The methodology followed has been the review of the number of occurrences collected in a time horizon of 2 years, this was compared with a simulation in the Arena system under an improvement model based on 6 pillars of TPM and OEE. The results with the proposed improvement, evaluated in one year, show an increase of the indicator with an average availability of 74.04%, an average performance of 85.8% and an average quality 50% of the equipment, obtaining an average OEE indicator of 83.01%, which is generated as a result of the product of the monthly values of availability, performance and quality. / Trabajo de Suficiencia Profesional