<p>This master’s thesis was performed during the fall of 2006 at Cloetta Fazer AB in Ljungsbro. Cloetta Fazer is the market leader in Scandinavia of manufacturing confectionary and chocolates. The purpose of the project has been to identify causes that impact the quantity of waste in production as well as a cost/benefit analysis of the solutions that can reduce the problem of production waste.</p><p>The work includes four production lines that are individually designed depending on what kind of product that are produced on the line. By using qualitative and quantitative methods such as focus groups, interviews and observations data has been collected. To fully understand and get good knowledge of the processes was process mapping initially performed. The process mapping illustrated where in the process waste generates and what kind of destination it reaches, i.e. recycling, animal food, the company factory store or deposit. Focus groups with production personnel and salaried employees were created to discuss the types of waste that occurs in production and what it depends on. These causes were categorized and many problems was considered product related but also depending on the operators knowledge of the process. To get information of which of the causes that generate most waste, a production safety analysis has been performed. The method ties the causes to the result by sorting information of causes that leads to waste, stop and loss in production rate. The study has been performed on individual activities and complete processes depending on the information that was received with focus groups. The types of waste that arise are not only that the specific product is incorrect but also related to the process itself such as incorrect placement of the product before next activity on the line.</p><p>The solutions that have been developed during the project are mainly related to the process and demand reconstruction or additions to the process. By assessing the solutions with respect to how much savings they generate, how long its takes to implement, cost of investment and pay-back time, an order of precedence has been created to reach awareness of the most advantageous solutions.</p>

This master’s thesis was performed during the fall of 2006 at Cloetta Fazer AB in Ljungsbro. Cloetta Fazer is the market leader in Scandinavia of manufacturing confectionary and chocolates. The purpose of the project has been to identify causes that impact the quantity of waste in production as well as a cost/benefit analysis of the solutions that can reduce the problem of production waste. The work includes four production lines that are individually designed depending on what kind of product that are produced on the line. By using qualitative and quantitative methods such as focus groups, interviews and observations data has been collected. To fully understand and get good knowledge of the processes was process mapping initially performed. The process mapping illustrated where in the process waste generates and what kind of destination it reaches, i.e. recycling, animal food, the company factory store or deposit. Focus groups with production personnel and salaried employees were created to discuss the types of waste that occurs in production and what it depends on. These causes were categorized and many problems was considered product related but also depending on the operators knowledge of the process. To get information of which of the causes that generate most waste, a production safety analysis has been performed. The method ties the causes to the result by sorting information of causes that leads to waste, stop and loss in production rate. The study has been performed on individual activities and complete processes depending on the information that was received with focus groups. The types of waste that arise are not only that the specific product is incorrect but also related to the process itself such as incorrect placement of the product before next activity on the line. The solutions that have been developed during the project are mainly related to the process and demand reconstruction or additions to the process. By assessing the solutions with respect to how much savings they generate, how long its takes to implement, cost of investment and pay-back time, an order of precedence has been created to reach awareness of the most advantageous solutions.

The waste of material is a big expense for manufacture companies caused by lack of quality. The cost by lack of quality often totaled to a big percentage share of the turnover when all cost related to lack of quality is included. New manufacturing systems like Lean production or Just In Time demands better internal quality for the manufacturer. To make those manufacturing system with small and none buffer stock successful the quality improvement continuously have to be developed. Measuring of waste of material in Bubs Candy’s factory where not simple due to the products does not have a permanent weight during the manufacturing process. The weight of Bubs Candy’s products vary depending where in the manufacturing chain it’s located because of vary in the water content. With different measurement and examination the problems have been removed and good opportunities for calculate and enter the waste of material have been created. A large number of measures to reduce the waste of material in the production have been formed. The measures are based in facts from interviews, measurements and observations. The examinations are made especially in a part of the production there the products are casted. The results of this grad work are solving proposals, full or partly, for the problems that have been identified. Documents for follow up the quality work have been created. Together with proposals for active quality improvement, Bubs get good opportunities to develop their production and reach increased efficiency, profit and quality.

<p>The waste of material is a big expense for manufacture companies caused by lack of quality. The cost by lack of quality often totaled to a big percentage share of the turnover when all cost related to lack of quality is included. New manufacturing systems like Lean production or Just In Time demands better internal quality for the manufacturer. To make those manufacturing system with small and none buffer stock successful the quality improvement continuously have to be developed.</p><p>Measuring of waste of material in Bubs Candy’s factory where not simple due to the products does not have a permanent weight during the manufacturing process. The weight of Bubs Candy’s products vary depending where in the manufacturing chain it’s located because of vary in the water content. With different measurement and examination the problems have been removed and good opportunities for calculate and enter the waste of material have been created.</p><p>A large number of measures to reduce the waste of material in the production have been formed. The measures are based in facts from interviews, measurements and observations. The examinations are made especially in a part of the production there the products are casted.</p><p>The results of this grad work are solving proposals, full or partly, for the problems that have been identified. Documents for follow up the quality work have been created. Together with proposals for active quality improvement, Bubs get good opportunities to develop their production and reach increased efficiency, profit and quality.</p>