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Within the Master’s program in mechanical engineering at Linköping University, this thesis project unfolds in collaboration with Metso Sweden, specifically at their Sala factory. Focused on addressing challenges in packaging processes for Metso’s VASA-line slurry pumps, the project endeavors to devise a concept that not only meets global shipping requirements but also enhances factory output. The research unfolds with an exploration of the background, emphasizing the complexities of manufacturing large-scale pumps for heavy-duty industries. Operating in 45 countries with a workforce of approximately 16,000 employees, Metso’s site in Sala specializes in pump production, particularly for the mining industry. The unique nature of slurry pumps, designed to handle liquid solutions containing solid particles, necessitates a tailored approach to packaging. The identified problem lies in the high variation of pump configurations, demanding flexibility in production and packaging. Currently, custom-made packages are crafted by experienced operators, who are lacking feedback on their performance. The packaging process involves standard pallets or custom-made packages, with the latter lacking standardization and documentation, introducing uncertainties in transport. This study aims to improve overall efficiency at Metso by addressing bottlenecks and knowledge gaps in packaging, focusing on the VASA-line slurry pumps. The goal is to present a concept that aligns with global shipping requirements and has the potential to significantly increase factory output. The findings, supported by production analysis and a detailed implementation plan, estimating a 3.38-fold increase in current production capacity. The thesis utilizes production analysis methods in supporting product development and optimizing packaging processes. It further highlights the influence of global shipping requirements on production dynamics, necessitating additional steps in package assembly. With a focus on time rather than costs, this thesis positions itself as a practical guide for enhancing production efficiency within a constrained time frame. In summary, this thesis unfolds as an exploration of packaging challenges, offering tangible insights for product development in a production setting and package development, especially in the context of global shipping.

The development of advanced manufacturing opens new possibilities regarding cooperation between robots and humans, leading to a more sustainable industry. The study aims to research how automated processes with collaborative applications can be implemented in manual production systems and analyse the economic and ergonomic consequences this leads to. The process examined in the thesis is the de-labelling of wooden pallets conducted at the case company Volvo Construction Equipment in Braås, Sweden. Both quantitative and qualitative methods have been used. The study started with an analysis of the current situation regarding process design and the ergonomic aspect. The equipment needed to design the robot cell for testing had to be evaluated before a simulation of the automated process was done. Finally, the concept was tested in a laboratory environment. The result of the study shows that it is possible to automate if the removal of the labels is carried out completely perpendicularly. The economic analysis shows that the automated solution becomes a cheaper alternative after one year and four months. When the current manual process consists of unsustainable ergonomic elements, an automated solution will lead to improvements and more sustainable physical and organisational ergonomics. / Utvecklingen av avancerad tillverkning öppnar upp för nya möjligheter med samarbeten mellan människa och robot, vilket leder till en mer hållbar industri. Denna studie syftar till att undersöka hur automatiserade processer med kollaborativa applikationer kan bli implementerade i manuella produktionssystem och analysera de ekonomiska och ergonomiska konsekvenserna detta leder till. Processen som granskats är avtagandet av etiketter från träpallar som genomförts på fallföretaget Volvo Construction Equipment i Braås, Sverige. Både kvantitativa och kvalitativa metoder har använts. Studien började med analys av den nuvarande situationen gällande design av process och den ergonomiska situationen. Utrustningen som behövdes för att designa robotcellen utvärderades innan en simulering av den automatiserade processen gjordes. Seden testades konceptet i laboratoriemiljö. Studiens resultat visar att det är möjligt att automatisera om avtagandet av etiketter genomförs helt vinkelrät från pallen. Den ekonomiska analysen visar att den automatiserade lösningen blir ett billigare alternativ efter ett år och fyra månader. Om den nuvarande manuella processen består av ohållbara ergonomiska element, kommer en automatiserad lösning leda till förbättringar och en mer hållbar fysisk-, kognitiv- och organisatorisk ergonomisk situation.