Abstract Today’s business environment involves a globalised market, greater than before competition and more challenging customers, all factors which contribute to higher uncertainty and variability. Manufacturing flexibility is becoming more important in order to cope with the complexity of products through frequency volume changes and evaluations of the technological requirements of products. The research for this thesis was performed within a subcontractor company, Laserkraft AB, who focus on laser cutting, turning and welding processes in their production. The company utilises a variety of volume and product mixes, which is in correlation with the objective of this study. The purpose of this research was to investigate the common source drivers in order to achieve volume and product mix flexibility on batch production systems. First, a literature review was conducted in order to build the framework of common source factors between volume and product mix flexibility. Then, a single case study was conducted to examine the outcomes of framework on batch production. In this case, qualitative techniques included interviews and an observation of the shop floor. The analysis of this study was conducted with empirical research on a case study and theoretical framework from literature. From the literature stand point; it was found that flexible manufacturing competencies (FMC) and strategic flexibility approaches are two main elements to determine internal source drivers between volume and product mix flexibility. The groups of common source factors were then analysed with respect to characteristics of batch production systems at the chosen company. A comparison between the framework and the empirical findings identified source drivers in order to achieve volume and product mix flexibility. Due to the limited nature of the study, all source factors that have an impact on achieving volume and product mix flexibility might not be presented in this thesis. Besides, it is difficult to generalise the result on a single case study. As a result, each organisation and industry refers to their product, process and type of layout, and requires a group of practices to achieve volume and product mix flexibility. This thesis concludes with the top three common source factors between volume and product mix flexibility such as: set-up time reduction, multi-trained employees and advanced manufacturing technology.

Today’s competitive global market has placed companies under great pressure and the focus on production systems has been more prominent. Although there are several claimed benefits with using frameworks in the development of production systems, companies are reluctant to use these. Consequently, a relevant question formulation is: Are frameworks in the development of production systems usable? The purpose with this thesis work was therefore to evaluate the usability of production system development frameworks (PSDFs) in practice. In order to achieve this purpose, two research questions were established: RQ1.  How can usability of frameworks be evaluated? RQ2.  How does the use of a framework contribute to the development of a new production system? In order to answer the posed research questions, Bellgran and Säfsten’s PSDF was used in the production system development (PSD) process of a new production system at Xylem. Based on the PSD process, a meta-study was performed to evaluate the practical usability of the PSDF. Usability was defined and evaluated based on the five usability terms learnability, memorability, efficiency, effectiveness, and satisfaction. The result showed that all the five usability terms contribute to the usability evaluation of PSDFs. However, memorability was considered difficult to use on only one study since the user has to think a step further and make a qualified guess to answer if it is possible to memorize a framework. Therefore, it was considered memorability is only appropriate to use in a multiple study. The results also showed that Bellgran and Säfsten’s PSDF contributed most in the beginning of the PSD process by putting emphasis on the planning phase and providing a structure to follow. Due to the nature of a framework (i.e., to serve as a guide for structures to follow), this was not unexpected. However, the contributions from a structure or plan are hard to exactly distinguish. Since companies most often want tangible and accurate evidences, frameworks’ vague contributions are considered to be a major reason to why companies do not use frameworks more frequently.

Manufacturing Industry as an important part of European and Swedish economy faces new challenges with the daily growing global competition. An enabler of overcoming these challenges is a rapid transforming to a value-based focus. Investment in innovation tools for production system development is a crucial part of that focus which helps the companies to rapidly adapt their production systems to new changes. Those changes can be categorized to incremental and radical ones. In this research we studied the Obeya concept as a supporting tool for production system development with both of those approaches. It came from Toyota production system and is a big meeting space which facilitates communication and data visualization for a project team. Four lean companies have been studied to find the role of such spaces in production development. Results indicate a great opportunity for improving those spaces and their application to radical changes in production development projects / EXPRES

In product manufacturing, assembly approximately represents 50% of the total work hours. Therefore, an efficient and fast assembly system is crucial to get competitive advantages at the global market and have the right product quality. Today, the verification of the assembly system is mostly done by utilizing software based simulation tools even though limitations have been identified. The purpose of this thesis is to identify when the use of additive manufacturing technology could be used in assessing the feasibility of the assembly system design. The research questions were threefold. First, identifying limitations that are connected with the used assembly simulation tools. Secondly, to investigate when additive manufacturing can act as a complement to these assembly simulations. Finally, to develop a framework that will assist the decision makers when to use additive manufacturing as a complement to assembly simulations. The researchers used the method of case study combined with a literature review. The case study collected data from semi-structured interviews, which formed the major portion of the empirical findings. Observations in a final assembly line and the additive manufacturing workshop provided valuable insights into the complexity of assembly systems and additive manufacturing technologies. In addition, document studies of the used visualization software at the case company resulted in an enhanced understanding of the current setting. The case study findings validate the limitations with assembly simulations described in theory. The most frequent ones are related to visibility, positioning, forces needed for the assembly operator, and accessibility between different parts. As both theory and case study findings are consistent in this respect, simulation engineers should be conscious of when to find other methods than simulation for designing the assembly system. One such alternative method is the utilization of additive manufacturing. The thesis outlines a number of situations where additive manufacturing indeed could act as a complement to assembly simulation. The authors argue that the results and findings to a large degree are applicable to other industries as the automotive sector is very global and competitive in nature and encompasses a large variety of complex assembly operations. A structured framework was also developed that could act as a decision support. The framework takes into account three dimensions that are crucial for the decision; (1) the assembly simulation limitation, (2) the context of the assembly and which parts are involved and (3) the possible limitations of additive manufacturing in the specific context. This impartial decision framework could help companies with complex assembly systems to know when to use additive manufacturing, as well as for which parts and subparts additive manufacturing is applicable. To increase the longevity of the decision framework, new improvements of assembly simulation tools and additive manufacturing technologies, respectively, should be incorporated in the framework.

Current industrial companies are highly pressured by growing competitiveness and globalization, while striving for increased production effectiveness. Meanwhile, flustered markets and amplified customer demands are causing manufacturers to shift strategy. Hence, international companies are challenged to pursue changes, in order to continue being competitive on global markets. Consequently, a new industrial revolution has taken place, introduced as Industry 4.0. This new concept incorporates organizational improvement and digitalization of current information and data flows. Accomplished by data from embedded systems through connected machines, devices and humans into a combined interface. Thus, companies are given possibilities to improve current production systems, simultaneously saving operational costs and minimizing insufficient production development. Smart Factories, being the foundation of Industry 4.0 results in making more accurate and precise operational decisions from abilities to test industrial changes in a virtual world before real-life implementation. However, in order to assure these functions as intended, enormous amount of data must be collected, analysed and evaluated. The indicated data will aid companies to make more self-aware and automated decisions, resulting in increased effectiveness in production. Thus, the concept will clearly change how operational decisions are made today. Nowadays, Discrete Event Simulation is a commonly applied tool founded on specific data requirements as operational changes can be tested in virtual settings. Accordingly, it is believed that simulation can aid companies that are striving for implementing Industry 4.0. As a result, data requirements between Discrete Event Simulation and Industry 4.0 needs to be established, while detecting the current data gap in operational context. Hence, the purpose of this thesis is to analyse the data requirements of Discrete Event Simulation and Industry 4.0 for improving operational decisions of production systems. In order to justify the purpose, the following research questions has been stated:   RQ1: What are the data challenges in existing production systems? RQ2: What data is required for implementing Industry 4.0 in production systems? RQ3: How can data requirements from Discrete Event Simulation benefit operational decisions when implementing Industry 4.0?   The research questions were answered by conducting a case study, in collaboration with Scania CV AB. The case study performed observations, interviews and other relevant data collection to accomplish the purpose. In parallel, a literature review focusing on data requirements for operational decisions was compared to the empirical findings. The analysis identified the current data gap in existing production systems, in correlation to Industry 4.0, affecting the accuracy of operational decisions. In addition, it was shown that simulation can undoubtedly give positive outcome for adaptation of Industry 4.0, and a clear insight on data requirements.

Introduction The implementation or transfer of production systems from the developing organisation to the receiving can induce difficulties, however a connection between achieving readiness of the receiver within the context of PSD has not been investigated previously. The aim of this thesis is thus to examine PSD in a core plant environment, focusing on the transfer activity and readiness for change. The following research questions were asked: How can assessing readiness potentially benefit a PSD project? How can preparation for transfer ensure readiness of the receiving organisation? Methodology A case study was performed and a company was selected due to a recently performed PSD project where the company went from a tradition line-based production to digitalised cells. The thesis is within the COPE research project; thus, some emphasis is on the global aspect. This exploratory and descriptive research study both examines and describes the studied phenomenon. The case study approach enabled the identification of organisational and human factors within the PSD project. Data collection contained interviews and a literature review was performed. Theoretical Framework A literature review was performed which provides insights regarding a general approach to a PSD process. Furthermore, core plant role and the strategic position within the network are described. Other investigated areas are within transfer of; processes, production and knowledge as well as prerequisites for those activities. Maturity assessment models are also introduced to provide an insight on assessing an organisations current state and to establish improvement strategies. An overview of competences which are required in an Industry 4.0 context are presented. Individual and organisational effect on change are presented as well as how change can be combated. Empirical Findings The empirical findings provide an overlook of the current manner in which PSD projects are executed, foremost by investigating a recent PSD project. The investigated aspects were more concretely regarding the need for a readiness assessment, and readiness to transfer a PSD project from the developing to the receiving organisation. Motivation to change and change management were also identified. Lastly, replicability within the core plant context were examined. Analysis and Discussion Possible benefits of a readiness assessment are identified, which are creation of a holistic view, alignment of vision, standardisation need and communication among other things. Participation and assignment of responsibility are also identified as lacking within the case company which is an essential asset within a PSD project. Lastly a framework is developed which can possibly guide the PSD process in achieving readiness for change. Conclusions and Recommendations Multiple benefits of a readiness assessment are identified which emphasises the human and organisational aspects of a change implied by a PSD project. The technical focus identified in the case company can be combated by acknowledging soft variables and skills and by understanding the decisions behind solutions. A framework is developed for Readiness Assessment with a focus on contesting the lack of responsibility and a “we against them” attitude. The mission of the framework is to create alignment and collaboration. / COPE / XPRES

In order to meet the expectations of today’s market and compete in the global world we live in, many companies are facing changes. A low cost production and high quality is not enough to be competitive. Companies must also satisfy the external customers’ claims, which to a great extent imply demands on an increased productivity. It is not enough to look to the external customers. The people working within the production system are the internal customers and the production system must be designed to suit their needs. Increased productivity can be stressful for operators, especially in the automotive industry, where heavy and frequent lifting is part of the daily work. The increased competition can thus in the long run lead to consequences for operator health as a result of heavy, and frequent, lifting. Due to this, more companies are looking over the possibilities to automate parts of their production process. The purpose of this thesis is to explore, using simulation tools, how automation of heavy lifting can affect productivity and work environment in processing or manufacturing processes. The research questions that will be answered are: o In what way does automation affect productivity in processing processes? o How can simulation tools act as an aid in designing automation? o What impact does automation have on the operator’s ergonomic work environment? To answer these questions, a literature study has been conducted in three main areas: production development, automation and simulation. A case study was carried out in a processing cell within the heavy vehicle industry, which currently does not have an approved ergonomic working environment. The company wanted to implement a robot and the purpose was to investigate how ergonomics and productivity was affected. The comparison was made using a simulation created in the ExtendSim software. The purpose of the simulation was to compare the current production system with a layout where a robot was implemented in the system. From this thesis, the conclusions were drawn that automation can affect a company’s productivity in a positive way provided that the preparatory planning is carried out thoroughly. The thesis shows that a simulation tool can be helpful from a number of aspects when automation is to be designed, and not least that it can undoubtedly be positive for the operator’s ergonomic work environment to automate parts of the production that includes heavy and frequent lifting.

In the pursuit of excellence industrial companies are increasingly employing production system development to rationalize their processes. One such approach that has been employed to great extend in the automotive industry is that of introducing modularity to the product design. This shift from integral products to modular ones, is associated with a higher level of standardization of parts and processes. However, researchers are still mapping out this correlation. As the connection between modularity and the recorded effects is still up for discussion, still fewer studies have been made on how to most effectively adopt modularisation. This thesis is therefore a research that explores the relationship between product design and production from a perspective of production system development. It is a collaborative study conducted with a manufacturer of industrial robots that is preparing to transition from an integral product design to a modular one. The case study utilizes discrete – event simulation to model the impact of such a changeover in the production system. Not resulting in a step-by-step how-to guide, the study nevertheless shows that discrete – event simulation can prove to be a valuable asset both when analysing what-if scenarios and when pinpointing pre-emptive measures in order to mitigate any negative disruption such a transition might initially bring.

Process automation for discrete manufacturing excellence (PADME)

Production system development is challenging for manufacturing companies, and development of HMLV production cells entails additional challenges. Thus, the aim of this study is to support the development of a HMLV production cell, and the following research questions were asked: RQ1: What are the challenges of developing a HMLV production cell? RQ2: What are the critical factors to consider when developing a HMLV production cell? RQ3: How can the development of a HMLV production cell be supported? A literature review in combination with a case study were performed to fulfill the aim and answer the research questions. The literature review was conducted to gain knowledge from previous studies, whilst the case study was performed to complement the theoretical findings. The selected case is the development of a HMLV production cell in the department of engine machining at Scania, which is planned to perform production activities for various departments of Scania. The primary data was collected through observations and interviews. The identified challenges of developing a HMLV production cell were production planning, utilization of equipment, product quality and material flow. The identified critical factors to consider when developing a HMLV production cell were production flexibility, production competence, production technology, pilot production, manufacturing strategy, order management system and standardization. The identified challenges of developing a HMLV production cell and the critical factors to consider when developing a HMLV production cell can support manufacturing companies by informing what challenges to expect prior to developing a HMLV production cell, and what critical factors can mitigate these challenges. Two ways of supporting the development of a HMLV production cell are recommended to Scania: creating a structured order management system and performing a pilot production for the milling operation of the core box reparation process. During this study, it was discovered that different HMLV production cells have different capabilities, challenges, and therefore also different critical factors. As such, recommendation for further research is to investigate how the development of different types of HMLV production cells can be supported by using a multiple case study research design, and to compare the challenges and critical factors for the development for the different types of HMLV production cells.