This final thesis was performed at Ecole Nationale Supériure D’Arts et Métiers (ENSAM) in Lille, France. The aim of the thesis has been to use two different simulation tools to analyse an existing production cell with focus on industrial engineering. The possible use and the usability of the simulation tools are also studied. The models built for simulation have been used to gather data about the cell. After analyse and discussion about the data we came to the following conclusions. The bottleneck in the cell is the Stäubli. A cheap and simple way to improve the cell is by adding new decision points (sensors) to it. The most efficient location of the new decision points is before and after the Stäubli. The production rate reaches its maximum rate for both settings with eight pallets. If the improvements are implemented then there is no reason to change the speed of the conveyor. With basic settings the speed can be increased for better productivity. The most efficient production type for short setup times is single, for both settings. Delmia is useful for visual representation. It’s also useful for measurements of time and distance since the accuracy is very high. Delmia is useful as common platform when to discuss and explain thoughts and ideas about a project. Flow simulation in Quest provides a great understanding of the production and the behaviour of the cell. It is very easy to get data in and out of the program and to compare results and impacts of changes.

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The machining operations that shape a metal component produce a raised edge or small pieces of material remaining attached to a work piece called burrs and sharp edges. The deburring process is intended to remove these imperfections and produce specific edge profiles. Burr formation during machining operations is one of the most significant problems encountered by industrial companies in component manufacturing. Remaining burrs after machining pose a severe risk for component breakdowns, if the burrs get loose. All work piece edges must therefore be completely defect-free. In the machining industry manual methods are commonly employed for burr removal. Fully automating deburring operations present a major challenge. Furthermore, removal of internal burrs of various sizes and shapes from parts sometimes becomes an extremely difficult task which causes high cost for labor, time losses, and health and safety risks. Increasingly, manufacturers are expected to deliver burr-free parts to their customer. Sandvik Coromant, Scania and Volvo Cars are three of these manufacturers, and these three companies have agreed to contribute to this thesis. Sandvik Coromant AB is part of the global enterprise Sandvik Group AB, and is world- leading in providing and developing cutting tools for the metal working industry. The company operates in over 60 countries worldwide and its main production plant is located in Gimo, Sweden [www.sandvik.com]. Scania is a global automotive industry manufacturer of commercial vehicles—specifically heavy trucks and buses. It also manufactures diesel engines for motive power of heavy vehicles, marine, and general industrial applications. Scania was founded in 1891 in Södertälje, Sweden. Today, Scania has ten production facilities worldwide [www.scania.com]. Volvo Car Corporation is an automobile manufacturer founded in 1927, in Gothenburg, Sweden. Volvo Cars has approximately 2,300 local dealers and around 100 national sales companies worldwide. Volvo Car Engine is a part of Volvo Cars. Volvo Car Engine produces engines and other components for other units, and it is headquartered in Skövde, Sweden [www.volvocars.com]. All of the companies above have problems in burr minimizing and removing strategy in machining and deburring operations to achieve quality assurance. Therefore, to choose a deburring system, and to reveal the results of deburring operations, it is necessary to be able to inspect/measure burrs. But, unfortunately, most industrial companies today lack the specialized systems to measure the presence of burrs, which adversely affect the overall deburring process. In this thesis, different types and sizes of work pieces have been taken directly from the production to measure burrs, and conduct experiments on them. The thesis focuses on three areas: A survey of the current deburring problems, including burr classification and measurement, current minimization strategies of burr formation, and current deburring methods. Experiments on new and improved deburring methods, including deburring tools (e.g. drilling deburring tools, countersink tools, grinding tools and alumina fiber brushes), water-jet deburring (multi-nozzle rotary lance jets, pure and abrasive single rotary nozzle water jets). A selection matrix as a thesis conclusion which relates these methods to criteria of deburring processes, such as process performance, industrial applications, quality assurance, safety and environment, costs, etc. This matrix can be a basis for a more detailed selection/decision matrix in the future. / QC 20101203

The wheel loader is a very versatile machine hence the layout of the machine and the software has to be a compromise of all the possible application. If the machine could detect the application and adapt the software settings to optimize the machine for the current application more application unique settings would be possible. To make the application identification cost efficient and possible to implement over the whole product range a minimum of added product cost is preferred. Therefore only using existing sensors of a wheel loader and using a software algorithm for the identification is suggested. In the following chapters three common applications are described from a generic point of view. The identification can be divided into different sections days, series, cycles and phases. The declaration of the phases is meant to be consistent regardless of application, however some phases may not be present in some application, 18 phases are identified to cover all application. Algorithms are developed to identify three different applications, bucket, pallet, timber and two different material classes. It is stated that it is possible to differentiate at least two different material classes with the suggested algorithms.

This thesis was conducted in the field of Environmental technology for the Sustainability & Technology Assessment group, at Singapore Institute of Manufacturing Technology. Singapore Institute of Manufacturing Technology is a research institute, striving to contribute to Singapore’s industrial capital through use-inspired research. The manufacturing industry contributes to a significant portion of the world´s total energy and resource consumption. This resource consumption could be reduced significantly through sustainable initiatives and technologies already available today. The reasons why companies choose not to invest in such technologies are often not due to technical factors, but rather due to financial factors. Financial barriers exist because investments are made on the basis of cost based value systems, which seldom justify investments in sustainable technology. When investments are made, the primary reason is to reduce costs while intangible benefits are ignored. However, this study shows that sustainability creates intangible value that current value systems cannot account for. Understanding the true value of sustainability would help decision makers realize that sustainable manufacturing is a viable business opportunity. This thesis studies the effect sustainable attributes has on a company’s ability to generate value. A value system is proposed, linking 40 sustainable attributes to value domains of intangible value. The value of sustainable attributes is quantified using the Sustainable Value approach. The study shows that social indicators, deemed by others to be unsuitable, can be used when proper adjustments to the Sustainable Value approach are made. A case study was performed on the Swedish manufacturing company Finess Hygiene AB to investigate the applicability of the model. The case study showed that the value system was applicable using data that already exists within the company, but the main challenge lies in collecting good and reliable benchmark data. Benchmark data is significantly easier to obtain in Sweden than Singapore for users wishing to apply the proposed value system. A follow up study should be performed to study the potential of a large scale adoption of the value system in Singapore.

This master thesis project was initiated in connection to the research project “Green Production Systems”, which is being conducted at Mälardalen University with involvement of academics and Swedish automotive and manufacturing industries. This thesis is prepared in guidance of “Development of guidelines for environmental value improvement and cost decrease” work package and the work package associated “Lean and Green Production Systems” master thesis proposal (see Appendix I). The aim of the thesis is to provide the work package with an international aspect under the given master thesis proposal scoping. The main objective of this thesis has been to contribute to a further understanding of how approaches to lean and green can be used to develop competitive production systems. A theoretical frame of reference has been presented in order to provide the research with a theoretical foundation. Further, empirical studies of four companies from China and Turkey have been carried out to investigate how companies perceive and work with their production systems in terms of applications of lean and green approaches. The empirical studies also aimed at identifying good examples of current practices that the companies achieved within the area.

Detta examensjobb utfördes på Stacke Hydraulik AB som tillverkar och säljer hydrauliska system. Uppdraget var att uppdatera deras befintliga verkstadslayout samt att studera om flödet för ”små och medelstora” rör går att förbättra. För att kunna optimera flödet var man tvungen att ta fram vilka/vilken process som var flaskhals, för att sedan kunna ge förslag på förändringar som kan leda till ett bättre flöde och en kortare ledtid. Studierna av flaskhals grundades på totalt 50 stycken cylinderrör, de mest tillverkade samt de som har störst volymvärde. Produktionsgrupp 117 (svarv) identifierades som flaskhals eftersom den tog längst tid i processen, men även produktionsgrupp 118 (svarv) är en flaskhals. 26 % av cylinderrören hade produktionsgrupp 117 som flaskhals medan 24 % hade produktionsgrupp 118. För att optimera produktionsflödet för dessa rör krävs det att man använder produktionsgrupperna effektivt med minimerat slöseri. Ett alternativ till förbättring skulle kunna vara en utökad maskinpark för tillverkning av dessa rör. / This examination-work was performed at Stacke Hydraulik AB. They are manufacturing and selling hydraulic systems. The commission was to update theirs excisting layout of the industry and to study if there are some possibilities to improve the flow of “small and medium-sized” pipes. To optimize the flow you had to identify which process that could be a bottleneck. And after that try to give some proposals on changing that could lead to a better flow and a faster lead-time. This study of bottlenecks was based on 50 pieces cylinder pipes of that type they mostly manufactured and also the pipes that got the highest volume value. Production group 117 (lathe) was identified as a bottleneck because it took the most of the time in the process, but the production group 118 (lathe) was also a bottleneck. 26 % of the cylinder pipes had production group 117 as a bottleneck while the production group 118 had 24%. To optimize the production flow of those pipes it will demand that they should use the production groups more effective with a smaller waste of resources. An alternative to improve manufacturing process could be to invest in a bigger machinery plant of those pipes.

På ABB i Ludvika tillverkar man en mängd produkter för högspänningsanläggningar. En av dessa produkter är ventilavledare. Ventilavledaren är en säkerhetsapparat som ska skydda övrig utrustning mot förekommande överspänningar. Ventilavledarna som tillverkas i Ludvika är gjorda för system från 52kV upp till 800kV, vilket är den högsta spänningen som används i världen idag. Idag finns två varianter av ventilavledare en med porslinisolant och en med polymerisolant. På ABB ser man att kunderna mer och mer eftersträvar polymeravledare. Polymeravledare har p.g.a. mekaniska begränsningar inte kunnat användas i system med högre spänning än ca. 245kV. För att kunna erbjuda polymeravledare för högre spänningar har en ny produkt tagits fram. Den nya produkten kallas PEXLIM Stark. Med den nya produkten innebär en mängd processer som måste arbetas fram. En sådan process är slutmontaget där man monterar de sista detaljerna. Detta arbete har gjorts för att se vilka problem som kan uppstå vid slutmontaget och hur man löser dessa på bästa sätt. / ABB has a big factory in Ludvika where many kinds of apparatus for high voltage systems are manufactured. Among the products are surge arresters, which are used to protect other equipments in power systems against all type of transient overvoltages. The arresters manufactured in Ludvika are for voltage systems from around 52kV up to 800kV which is the highest system voltage level in the world so far. The active elements in the arresters are blocks of ZnO material. The arresters are manufactured utilizing two types of enclosures, porcelains and polymer. Due to the good response from the customers more and more arresters are manufactured with polymer housings but so far the mechanical strength has prevented polymer designs for higher voltages than approximately 245kV. In a new project, therefore, a polymer housed arrester with higher mechanical strength will be developed. The working name for the new product is PEXLIM Strong. Among all the problems which have to be solved during the development of the new product is also how the final assembly of the product shall be performed. In this report, as part of a Bachelor of Science in Machine Engineering, the problems are analyzed and different solutions to obtain an efficient final assembly of the new product are suggested.

The object of this examination project is to produce a method of work sampling at Rapid Granulator AB. The aim is to perform the method at the company and evaluate if it is executable. The study is delimited to the basic construction of the 45-series in the assembly hall. Preparations to produce the method of the work sampling resulted in definitions of activities, a form and a product tree. Several days were spent studying the assembling to learn and understand the entirety. The work sampling result showed a large amount of no value adding time that was used in the assembling. Some of the activities could be reduced and we observed some problems during the assembly process. These problems were noted and are presented to enlighten the company, together with some suggests of changes, with the purpose to reduce the time of the assembly cycle and increase the productivity. Conclusions of the results of the work sampling are discussed at the end. A large amount of tables and charts, connected to preparations and results, is to be found in the appendix.

Abstract My task was to prepare the already designed heating list “Stayhot” for manufacturing. I started with drawing the whole list in the CAD-program. It became obvious that some of the designed components had to be changed to work in practice. A turnable reflector couldn’t be combined with the isolation. The suggested light emitting diodes wouldn’t give enough light, so I cut them out and the problem with light remains to be solved. The old grating had many rods and I changed that to a grating with fewer rods to make it easier to clean. The hanging-up of the grating was also changed. The lower ceasing was changed to be closed towards the reflector to avoid filth and damp. The reflector had a different shape. From having been square it became oval to follow the shape of the above ceasing and have a more even isolation. It also opens up to the possibility to use two heating elements. The heating-source should have been changed to be warmer, but as the new elements didn’t come until my work was almost finished, I couldn’t use it.