A case study has been done at Dynapac Compaction Equipment AB in Karlskrona in order to improve the internal flow of the production. The “Supermarket Storage”, an adjoining storage that feed material to the lean production in the “Z-line” assembly line with the help of kitting, was chosen to be focused during the optimization of the internal flow. Also, due to the little academic research about kitting it was decided to focus the research on the kitting process and identify how to optimize it. The purpose of the research is to determine optimization methods of a kitting process and fill in the gap in the subject field about kitting optimization. Given the research time limit, the focus was only on the kitting process in the Supermarket Storage and no optimization could change the storage’s layout. This resulted in three research question that will be investigated in the thesis.  Which common approaches exist when it comes to optimizing a kitting process?  What is the result of each optimizing method in the time aspect?  When should an optimization method be used, compared to the other methods that will be tested in this research? In order to solve these questions, was a needfinding process used in order to identify the kitting process current problems and the needs of the employees. With this, three optimization methods were identified and selected to be used to optimize the kitting process; optimization of routing, optimization of family grouping and optimization of an electronic system. The optimization of routing focused on the route that the kitters travel and the optimization of the family grouping focused on the article distribution in the Supermarket Storage; there each kitting operation’s articles should be stored in the same zone. Finally, the optimization of the electronic system, investigated the possibility to utilize a pick to scan system with the kitting process. Each optimization was implemented in different field experiment in order to identify how each optimization affected the kitting process. This resulted in that each optimization had improved the kitting process time efficiency and the electronic system had the biggest impact. Some other results were also observed during the experiments. The route optimization improved the learning curve of the kitting process and the family grouping optimization decreased the bottlenecks in kitting process. The electronic system optimization also implemented new benefits that resulted in a profit 2.5 times the cost of the system. Some of the benefits include removal of unneeded processes, quality control of the kitting process and statistics gathering that can be used to improve the process in the future. These results imply that all three optimization methods can be used in order to improve the time efficiency of a kitting process in a similar storage layout. The routing optimization should be used in a kitting operation with a high rotation of new kitters. The family grouping should be used in a kiting process with bottlenecks in the process and low organization of the article distribution. Ultimately, the electronic system optimization should be used in a kitting process that has unneeded processes and has the need of new tools that the electronic system can implement.

La théorie du Lean est une forme d’organisation et de management communément adoptée dans l’industrie manufacturière et qui a fait ses preuves depuis plusieurs décennies. Le Lean apporte une philosophie basée sur la chasse aux gaspillages et supportée par des principes traduits en méthodes opérationnelles à appliquer pour gagner en efficacité. Alors que la recherche de l’efficacité a toujours été d’actualité chez les constructeurs, le Lean Construction apporte une nouvelle forme d’organisation opérationnelle et managériale. La littérature sur le Lean Construction fournit et explique les principes du « Lean en industrie » pour gagner en performance. En revanche, un gap existe encore entre ces principes et leur application effective en construction. On explorera l’adaptabilité des principes du Lean tout au long de la chaîne de construction avec des cas d’application concrets. Le premier et le deuxième chapitre introduisent le Lean en promotion immobilière en mettant en évidence le combat que mènent la plupart des entreprises de construction pour assurer la livraison en temps et en budget de leurs projets et ainsi assurer la satisfaction du client. Le troisième chapitre illustre un cadre structuré d’application du Lean en Etude de Prix. Les chapitres 4, 5 et 6 investiguent le Lean en phase de « Construction » et en particulier la logistique chantier au travers la pratique du Kitting. Cette pratique émergente en construction sera liée à la théorie du Lean et le chapitre proposera un modèle d’implémentation du Kitting avec une application sur 3 chantiers-tests expérimentaux. / Lean theory (also referred to as Lean Management or Lean) is a systematic way of thinking, first developed in the manufacturing industry, to eliminate waste. Concrete and practical by nature, this new “way of managing the production” affects the day-to-day practices and eventually aims at rationalizing the processes through the application of operational methods. While construction practitioners and researchers have always been concerned with the issue of efficiency, Lean theory applied to construction offers new alternative forms of organizing the production in the construction industry. However, more research is required to fill the existing gap between these principles and their actual application in construction. Using infield case studies, we explore the adaptation of lean principles throughout the construction value chain. The first and second chapters introduce lean manufacturing in real estate development and highlight the struggle of majority of construction companies to complete projects on time and within budgets, thus ensuring customer satisfaction. The third chapter presents a structured framework for the application of Lean in the “Bidding phase”. Chapters 4, 5 and 6 explore the "Construction" phase and particularly site logistics through Kitting; we'll see how this new emerging practice in construction falls within the Lean theory. Finally, we wrap up with an implementation model that was tested in 3 experimental pilot projects

Purpose - The purpose of this study is to investigate potential for and cost related impact of internal lead time reduction through coordination between materials supply and a production activity of customer-order-unique products. In order to achieve the purpose two questions are answered; 1. How can with respect to sourcing strategy, coordination between materials supply and production activity of customer-order-unique products be achieved? 2. How does a coordination affect cost items in related areas of the business? Method – Based on literature in the area of materials supply a theoretical framework for the study was established. The company JELD-WEN, an industrial manufacturer with customer-order-unique-production of fire- and safety-doors was used for a case study. Data collection was performed through interviews, observations and document studies. A comparison between the theoretical framework and empirical data generated the final results. Findings – Using a hybrid sourcing strategy, changes in materials supply through an internal call-off together with the materials feeding method kitting proves potential to reduce the internal lead time in the manufacturing process. An economic impact of such coordination with a production activity has been found for three cost items; handling cost (increase), administrative order cost (increase/decrease) and inventory carrying cost (increase/decrease). Implications – The study does not contribute to new theory in the field. Instead existing theory and relations defined in the theoretical framework have been verified by the case study. Internal lead time reduction identified in the study may be used in other ways than by the means of an improved customer offer. This can be done through sharing time to other time-exposed activities in the manufacturing process or as an additional safety time for finished products to secure company's delivery accuracy. Therefore, in a decision situation for change affected cost items should be assessed in contrast to the more indirect value of a lead time reduction. Limitations – Modifications of materials supply occurs in a context where conditions outside the unit of analysis plays a crucial role and thereby limits the possible usage of the potential lead time reduction. The study handles impact of cost items in a general direction (increase or decrease). Absolute terms contribute to more precise consequences and are probably necessary to support a company's final financial decision of using an alternative approach in materials supply.

One of the key decisions for every assembly line is the decision about the materials feedingsystem which means the method of supplying materials to the operators. This decision affectsall of the other activities performed as well as the performance of the assembly line. In theindustry, kitting is practiced as a method of materials feeding among others such ascontinuous supply, batching and sequencing.Kitting is the name for the practice of feeding components and subassemblies to the assemblyline in predetermined quantities that are placed together in specific containers. In the industrykitting activities are used to solve the issues of:· Lack of space· Quality· Flexibility· Materials Handling· LearningKitting shows numerous benefits in all of five tracks if applied properly. Drawbacks of kittingare mostly caused by wrongly prepared kits, kitting too much or unnecessary parts. It isimportant to include all five of these aspects in business cases before the implementation ofkitting, otherwise kitting activities are likely to cause further problems.The main reason for kitting in Swedish industry is the space requirements. Most companiesare aware of other benefits such as quality and learning aspects but are not considering themas their most important reason to initiate kitting activities. Companies are also hesitant toinitiate kitting since it is an expensive solution compared to other solutions.The biggest limitation of kitting seems as increased number of materials handling and theuncertainty about the level of kitting. Past experiences made companies more hesitant aboutkitting implementations.Kitting in a lean production system is possible as long as kits are secured so that they are100% correct in the first place and there is no machine downtime caused by invalid kits.Additionally, waste should be continuously eliminated from kitting operations and workersshould be trained well to get involved with the processes. / Uppsatsnivå: D

Scania Luleå is a part of Scania CV that has approximately 50 000 employees in 100 different country´s and is a manufacturer of trucks, buses and power solutions. At Scania Luleå; side beams, chassi details and rear axle housings are manufactured. This master´s thesis was focused on a kitting station for rear axle housing production.  The purpose of this master thesis was to do a feasibility study and an investment justification for an automatic kitting station for this production line. The goal was to develop one or more concepts for an automatic kitting station, five key factors was taken in to account: reliability, cost of cell, cell size, need for operators, equipment and one-piece flow.  The scope for the project excluded transport to and from the kitting area, as well as future components or products.  This was obtained through different methods of concept generation, such as brainstorming and brainwriting, resulting in 12 different concepts, with concepts ranging from operators preforming the main work to other concepts that were fully automated. To evaluate the concepts, some calculations were made on the needs of the equipment, the cost both for investments and installations but also for the need for operators. After evaluation 2 concepts remained one with operators and one with robots.  A simulation was made to get a better understanding of the concept with robots and some detailed calculations was made for the concept with an operator. The purpose was that the simulation for the concept with one operator would take too long time to perform and would not give a better result or understanding than basic calculations.  Finally, two recommendations were made; one short term and the other one long term concept.

I industriföretag används managementverktyg för att utveckla och effektivisera verksamheten så att ledtider och slöseri reduceras i samtliga processer. Parker PMDE Trollhättan tillverkar hydraulikmaskiner. Sedan 90-talet har Parker bedrivit verksamhetsutveckling enligt management principer i Lean Production. Ett nästa steg i Parkers ständiga förbättringsarbete var att undersöka möjligheter att utveckla en materialsatsningsavdelning så att en person kan förse monteringen med material tillräckligt snabbt utan att extra resurser behöver tillsättas. I dagsläget råder det obalans gentemot takttider i monteringen och det tar längre tid för satsningen att plocka ihop fyra satser än vad det tar för monteringen att förbruka dessa satser.Målet med examensarbetet var att ta fram förbättringsförslag där en person får förutsättningar att plocka ihop material till montering av fyra hydraulikmaskiner på mindre än 16 minuter. Delmålen var att göra en kartläggning av tider och arbetsmoment vid satsningen. Avgränsningarna i projektet var att inte undersöka processer utanför satsningen. Examensarbetet utformades efter DMAIC-metodiken, som är en projektmodell för faktabaserad problemlösning och tydlig struktur. Metoderna som användes vid insamling av data var observationer och analys av videoinspelat material som utfördes i programvaran AviX Method. Videoinspelningarna kategoriserades som olika aktiviteter i satsningsprocessen där gång, plock, scannertid, förmontering och övrig tid var de största kategorierna. Arbetsmoment identifierades som var tidskrävande och ej tillförde värde i processen. Mätningarna låg till grund för generering av lösningsförslagen.Baserat på ovanstående resultat och med hjälp av brainstorming genererades lösningsförslag tillsammans med produktionstekniker och materialhanterare. De lösningsförslag som uppfyllde målet med projektet att plocka en 4-sats under 16 minuter var pick by voice, pick by light, ringscanner och flytt av kilpress. Pick by voice anses vara lösningen som företaget bör införa eftersom den reducerar plocktid, scannertid och är ett flexibelt system. Ytterligare två lösningsförslag togs fram som inte uppfyllde målet men uppfattas som värda för företaget att utreda vidare utifrån Lean Production och ergonomiska skäl. De lösningsförslagen som inte uppfyllde målen bestod av en förändring av plockrundan och införande av en magnetlyft. / In industries, the management tools of Lean Production are used to develop and streamline operations in a way to reduce waste and lead times in all processes. Parker PMDE in Trollhättan manufactures hydraulic machines. Since the 90´s, Parker has pursued business development under the management principles of Lean Production. One of the next steps in Parkers continuous improvement was to explore opportunities to develop a kitting department so that a worker could provide the assembly with the material quickly without surplus resources. In the current situation, there is an imbalance from the kitting station towards the tact times in the assembly station because it takes longer at the kitting station to pick materials for four hydraulic machines, than it takes for the assembly station to consume these kits of materials.The aim of the thesis was to develop suggestions for improvement where a worker could perform the kitting process in less than 16 minutes. The interim objectives were to do a survey of the times and activities within the kitting process. The boundaries of the project was not to examine processes outside the kitting station. The project was designed according to DMAIC methodology, which is a project model for fact-based problem solving and clear structure. The methods used in the data collection were observation and analysis of video footage applying the software called AviX Method. Video recordings were categorized as different activities in the kitting process such as transport, picking, scanner time, pre-assembly and uncategorized time. Activities that were time consuming and did not add value to the process were identified. These data measures were the basis for the solution proposals.Based on these results and using brainstorming, solution proposals were generated together with the engineers and material handlers. The solution proposals that met the objective of the project of picking a 4-set of materials in 16 minutes were: Pick by voice, Pick-by-light, Ring Scanner and Relocation of one pre-assembly operation. Pick by voice is considered to be the most appropriate solution for the company since it reduces picking times, scanning times and is a flexible system. Two more proposed solutions were developed that did not meet the objective of the project, but are considered worth investigating further based on Lean Production and ergonomic reasons. These proposed solutions consisted of changing the picking route and the installation of a magnetic lift.

Studien är utförd på ATEA logistics med syftet att skapa förståelse för hur man kan kombinera två olika plockmetoder i materialförsörjningen. Målet med arbetet är att ta fram en modell som beslutsunderlag för hur denna kombination ska se ut med hjälp av kunskap angående påverkande faktorer. Resultatet är framtaget genom litteraturstudie kring plockmetoder samt egna mätningar och observationer på fallföretaget. Det konstaterades med hjälp av ett faktabaserat beslutsunderlag i form av jämförelsetider att man kunde spara upp till 295 sekunder på en given plockrunda hos fallföretaget. Det har då konstaterats att man med hjälp av kvantifierbara beslutsmodeller kan skapa kortare ledtider i materialförsörjningen med hjälp av en kombination av plockmetoder. / This report is a case study, which was conducted at ATEA Logistics AB. It’s purpose was to create understanding of how a combination of two picking methods can be used in materials supply. From this understanding the goal was to design a decision making model for when each of the methods is to be used. Literarry research, time studies, observations and interviews have been used to reach this goal. By calculating comparative times for each method, with the use of a factual decision making model, it was determined that the case company could save up to 295 seconds in a single picking round. From this result it was concluded that by using quantifiable and factual decision models, materials supply can be made more efficient by the use of a combination of picking methods.

Cette thèse, réalisée en collaboration avec le Groupe Renault dans le cadre d’un projet d’automatisation du kitting, s’intéresse à l’optimisation du processus de kitting en termes de maximisation du temps de cycle. Pour cela, nous étudions différentes configurations de système de kitting hybride avec robots(s) et opérateur(s) travaillant en série et séparés par un stock de découplage. Le(s) robot(s) commence(nt) la préparation des kits de pièces puis le(s) opérateur(s) se trouvant dans la partie manuelle du kitting récupère(nt) cette préparation et la complète(nt) avec les pièces affectées à cette zone.Notre objectif est de développer un outil d’aide à la décision permettant d’évaluer la performance d’un kitting hybride et de simuler son fonctionnement dans une configuration donnée (layout, politique de picking, etc.) avant son déploiement physique.Tout d’abord, à travers une modélisation des opérationsélémentaires de kitting effectuées par des robots et des opérateurs (prise et dépose, déplacement, etc.), nous proposons un modèle de temps de cycle permettant d’évaluer la performance du système hybride en termes de temps de cycle. Ensuite, nous développons un modèle d’affectation de pièces (PLMNE) permettant de les répartir entre kitting robotisé et manuel. L’objectif est de minimiser les temps de cycle et d’équilibrer la charge de travail entre les deux modes de kitting. Le modèle est appliqué à deux études de cas pratiques issues d’une usine Renault. Les résultats permettent d’identifier les paramètres qui impactent le plus les temps de cycle et le choix d’affectation des pièces entre kitting automatisé et manuel. Enfin, nous développons un modèle de simulation afin de calculer la taille optimale du stock de découplage entre kitting automatisé et manuel dans le but de maximiser la cadence du système hybride de kitting. / In this thesis, conducted with Renault in the context of a kitting automation project, we are interested in the optimisation of kitting processes in terms of cycle time maximisation. To do so, we study different configurations of hybrid robot-operator kitting systems where robots (two types of robots considered) and operators are connected in series by an intermediate buffer (to decouple their activities). The robotic kitting area starts the preparation of kits then the operators in the manual kitting area retrieve the preparation of robots and complete with the remaining parts.Our objective is to develop a decision-making tool that assesses the hybrid system performance in a given configuration (layout, picking policy, etc.).First, through a modelling of elementary kitting operations performed by robots and operators (pick and place, travel, etc.), we develop a cycle time model to assess the performance of hybrid kitting systems. Then, we develop an assignment model that assigns parts (formulated as a mixed integer linear programming (MILP) problem) either to robotic or manual kitting areas with the objective of minimising cycle times and balancing workload between them. The model is applied to two case studies pertaining to a Renault plant. This analysis identifies the parameters that influence cycle times and the choice between robotic and manual kitting. Finally, we develop a simulation model to find the optimal buffer size between robotic and manual kitting so that throughput is maximised.

Studien genomfördes på Hydroware Technology AB med syftet att få ökad förståelse för monteringsprocessen i ett industriellt tillverkande företag, för att kunna visualisera helheten av processen samt kunna synliggöra icke värdeskapande aktiviteter. För att kunna uppnå syftet och besvara studiens undersökningsfråga gjordes en nulägesanalys för hela produktionen samt en fokuserad analys av den valda delprocessen. Vidare utfördes ett antal experiment för att undersöka hur olika variabler kunde påverka förbättringsarbetet. Resultatet av studien diskuterades och mynnade ut i ett antal rekommendationer, som fallföretaget kunde ha användning av i sitt effektiviseringsarbete. I de sista kapitlen redogjordes förslag för hur företaget skulle kunna förbättra sitt arbetssätt och bidra till en hållbar utveckling. Det finns fler förbättringsmöjligheter på fallföretaget och forskarna rekommenderar vidare studier för att effektivisera fler delprocesser och uppnå det önskade framtida tillståndet.

This piece of work is focused on getting particular logistics management process streamlined and on reasonable recommendations leading to improvement of the current state in any logistics company. In accordance with the thesis objective, respective working hypothesis is defined: "The correct implementation of the replenishment method as far as inventory management in a logistics company is concerned contributes to the reduction of the stock." The application of results is performed on the manufacturing site Honeywell Brno. The first section of the thesis explains logistics and its tools, processes within material and inventory management and other related theoretical issues. Further, methods that have been applied are described. Main part is focused on the streamlining the production process in the company using calculations that respect factors directly influencing a level of the stock. The comparison of Kanban and Kitting system is provided too. Last part is discussing the obtained results, their expected economic consequences and recommendations for potential implementation in logistics chains elsewhere.