This work is the final part of the Master of Science degree in Industrial Design Engineering towards Production Design, at Luleå University of Technology. This project has been conducted during the spring of 2017 at Alimak Hek. The task has been to analyze material handling, material presentation and why material shortages occur at the industrial hoists final assembly stations. To get an understanding of the system, interviews and observations were conducted. A literature study was carried out to find current knowledge and different solutions. To involve the workers in the process and to check if the problems were understood correctly a workshop was conducted. This was also an opportunity to discuss desired future state and ideas with the workers. Another way to look at potential solutions was through the benchmarkings. These were both conducted internally and at other companies where different solutions for material handling was studied.   The material in focus has been fastening material. This was stored in bins at racks. These racks were placed at the assembly stations and the two big racks have been the focus of this project. The problems at these storages has been that the refilling did not work as it was supposed to. The old system was an order list with which material could be ordered from the main storage at Alimak, this however is not used any more. The system of today is that the empty bins are collected and put on a pallet to be sent to the main storage for refilling. The problem with this is that the workers did not take the bins when they were empty but rather went to a different storage to look there. This meant that the material sometimes got totally emptied at all racks before the bins were sent to refilling. This made for urgent needs where workers had to go to the storage themselves to get something refilled. Another problem was that these storages were placed behind the fixed stations which made them hard to get to and see. The bins used in today’s system were not all marked the same way and an old system for numbering was still partly used. The bigger storages were divided so that one should have the stainless material and the other should have the galvanized/zinc-coated material. This together with the other aspects made it hard to know where the bins should be and sometimes all bins of one kind was put in the same rack.   To fix these problems different suggestions were made. The use of a two-bin system has been suggested because of its simplicity and the potential it has to avoid a lack of material to arise. The two racks of today should be combined into one and moved to a more visible place. This would make the refilling easier and reduce the need to search for material at different places. Two general layouts have been developed, and the open layout has been suggested to be implemented because of the accessibility it would bring to the system. The approximate size of the rack and bins needed have been put forward and different suggestion for order in the rack has been made. The marking of the bins and rack has also been discussed and this should be made distinct so it is easy to see and read.

Submitted by Luciana Sebin (lusebin@ufscar.br) on 2016-09-21T13:52:44Z No. of bitstreams: 1 DissVBF.pdf: 4418595 bytes, checksum: aaae3efb173c8760a1039251a31ea973 (MD5) / Approved for entry into archive by Marina Freitas (marinapf@ufscar.br) on 2016-09-23T18:23:48Z (GMT) No. of bitstreams: 1 DissVBF.pdf: 4418595 bytes, checksum: aaae3efb173c8760a1039251a31ea973 (MD5) / Approved for entry into archive by Marina Freitas (marinapf@ufscar.br) on 2016-09-23T18:24:01Z (GMT) No. of bitstreams: 1 DissVBF.pdf: 4418595 bytes, checksum: aaae3efb173c8760a1039251a31ea973 (MD5) / Made available in DSpace on 2016-09-23T18:24:10Z (GMT). No. of bitstreams: 1 DissVBF.pdf: 4418595 bytes, checksum: aaae3efb173c8760a1039251a31ea973 (MD5) Previous issue date: 2015-03-20 / Não recebi financiamento / The continuous demand growth for liquid fuels, alongside with the decrease of fossil oil reserves, unavoidable in the long term, induces investigations for new energy sources. A possible alternative is the use of bioethanol, produced by renewable resources such as sugarcane bagasse. Two thirds of the cultivated sugarcane biomass are sugarcane bagasse and leaves, not fermentable when the current, first-generation (1G) process is used. A great interest has been given to techniques capable of utilizing the carbohydrates from this material. Among them, production of second generation (2G) ethanol is a possible alternative. 2G ethanol requires two additional operations: a pretreatment and a hydrolysis stage. Regarding the hydrolysis, the dominant technical solution has been based on the use of enzymatic complexes to hydrolyze the lignocellulosic substrate. To ensure the feasibility of the process, a high final concentration of glucose after the enzymatic hydrolysis is desirable. To achieve this objective, a high solid consistency in the reactor is necessary. However, a high load of solids generates a series of operational difficulties within the reactor. This is a crucial bottleneck of the 2G process. A possible solution is using a fed-batch process, with feeding profiles of enzymes and substrate that enhance in the process yield and productivity. The main objective of this work was to implement and test a system to infer online concentrations of fermentable carbohydrates in the reactive system, and to optimize the feeding strategy of substrate and/or enzymatic complex, according to a model-based control strategy. Batch and fed-batch experiments were conducted in order to test the adherence of four simplified kinetic models. The model with best adherence to the experimental data (a modified Michaelis-Mentem model with inhibition by the product) was used to train an Artificial Neural Network (ANN) as a softsensor to predict glucose concentrations. Further, this ANN may be used in a closedloop control strategy. A feeding profile optimizer was implemented, based on the optimal control approach. The ANN was capable of inferring the product concentration from the available data with good adherence (Determination Coefficient of 0.972). The optimization algorithm generated profiles that increased a process performance index while maintaining operational levels within the reactor, reaching glucose concentrations close to those utilized in current first generation technology a (ranging between 156.0 g.L⁻¹ and 168.3 g.L⁻¹). However rough estimates for scaling up the reactor to industrial dimensions indicate that this conventional reactor design must be replaced by a two-stage reactor, to minimize the volume of liquid to be stirred. / A crescente demanda por combustíveis líquidos, bem como a diminuição das reservas de petróleo, inevitáveis a longo prazo, induzem pesquisas por novas fontes de energia. Uma possível solução é o uso do bioetanol, produzido de resíduos, como o bagaço de cana-deaçúcar. Dois terços da biomassa cultivada são bagaço e folhas. Estas frações não são fermentescíveis quando se usa a tecnologia de primeira geração atual (1G). Um grande interesse vem sendo prestado a técnicas capazes de utilizar os carboidratos deste material. Dentre elas, a produção de etanol de segunda geração (2G) é uma possível alternativa. Etanol 2G requer duas operações adicionais: etapas de pré-tratamento e hidrólise. Considerando a hidrólise, a técnica dominante tem sido a utilização de complexos enzimáticos para hidrolisar o substrato lignocelulósico. Para assegurar a viabilidade do processo, uma alta concentração final de glicose é necessária ao final do processo. Para atingir esse objetivo, uma alta concentração de sólidos no reator é necessária. No entanto, uma carga grande de sólidos gera uma série de dificuldades operacionais para o processo. Este é um gargalo crucial do processo 2G. Uma possível solução é utilizar um processo de batelada alimentada, com perfis de alimentação de enzima e substrato para aumentar produtividade e rendimento. O principal objetivo deste trabalho é implementar e testar um sistema para inferir concentração de carboidratos fermentescíveis automaticamente e otimizar a política de substrato e/ou enzima em tempo real, de acordo com uma estratégia de controle baseada em modelo cinético. Experimentos de batelada e batelada alimentada foram realizados a fim de testar a aderência de 4 modelos cinéticos simplificados. O modelo com melhor aderência aos dados experimentais (um modelo de Michaelis-Mentem modificado com inibição por produto) foi utilizado para gerar dados a fim de treinar uma rede neural artificial para predizer concentrações de glicose automaticamente. Em estudos futuros, esta rede pode ser utilizada para compor o fechamento da malha de controle. Um otimizador de perfil de alimentação foi implementado, este foi baseado em uma abordagem de controle ótimo. A rede neural foi capaz de predizer a concentração de produto com os dados disponíveis de maneira satisfatória (Coeficiente de Determinação de 0.972). O algoritmo de otimização gerou perfis que aumentaram a performance do processo enquanto manteve as condições da hidrólise dentro de níveis operacionais, e gerou concentrações de glicose próximas as obtidas pelo caldo de cana-de-açúcar da primeira geração (valores entre 156.0 g.L ¹ e 168.3 g.L ¹). No entanto, estimativas iniciais de ⁻ ⁻ aumento de escala do processo demonstraram que para atingir dimensões industriais o projeto do reator utilizado deve ser analisado, substituindo o mesmo por um processo em dois estágios para diminuir o volume do reator e energia para agitação.