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Remanufacturing is an environmentally sound material recovery option which is essential to compete for sustainable manufacturing. The aim with remanufacturing at a majority of companies is to prolong physical product performance by delivering the same or betterthan-original product quality. In general, remanufacturing is an industrial process that brings used products back to useful life by requiring less effort than is demanded by the initial production process. Consequently, from a product life-cycle perspective, remanufacturing generates great product value. Remanufacturers lag behind manufacturers since they often face complex and unpredictable material and information flows. Based on a review of remanufacturing research, remanufacturing challenges in material and information flows can be classified into three groups: insufficient product quality, long and unstable process lead times, and an unpredictable level of inventory. While some remanufacturing researchers state that manufacturing and remanufacturing are significantly different, they have more in common than many other processes operations. Therefore, to sustain competitive remanufacturing, companies investigate an opportunity for improvement through the employment of lean production that generates significant benefits for manufacturers. In order to investigate the potential to address remanufacturing challenges by lean production, a Minimum time for material and information flow analysis (MiniMifa) method was developed. This method originates from the value stream mapping (VSM) method, broadly practiced to bring lean to manufacturing companies. The focus of MiniMifa was to collect empirical data on the identified groups of remanufacturing challenges from the remanufacturing perspective, and to provide a basis for the development of improvements originating from lean principles. Lean production was selected for this research due to its system perspective on material and information flows. Among the defined lean principles in remanufacturing, a pull principle was investigated at the case companies. The suggested principle demonstrated a reduction in lead time, followed by improvements in inventory level and product quality. However, in order to become lean, remanufacturers have to overcome three levels of lean remanufacturing challenges: external and internal challenges as well as lean wastes. Finally, this research reduces the gap between academia and industry by contributing with a possible solution to the identified remanufacturing challenges in material and information flows.

In recent decades, the development of computer-controlled manufacturing by adding materiallayer by layer, called Additive Manufacturing (AM), has developed at a rapid pace. The technologyadds possibilities to the manufacturing of geometries that are not possible, or at leastnot economically feasible, to manufacture by more conventional manufacturing methods. AMcomes with the idea that complexity is free, meaning that complex geometries are as expensiveto manufacture as simple geometries. This is partly true, but there remain several design rulesthat needs to be considered before manufacturing. The research field Design for Additive Manufacturing(DfAM) consists of research that aims to take advantage of the possibilities of AMwhile considering the limitations of the technique. Computer Aided technologies (CAx) is the name of the usage of methods and software thataim to support a digital product development process. CAx includes software and methodsfor design, the evaluation of designs, manufacturing support, and other things. The commongoal with all CAx disciplines is to achieve better products at a lower cost and with a shorterdevelopment time. The work presented in this thesis bridges DfAM with CAx with the aim of achieving designautomation for AM. The work reviews the current DfAM process and proposes a new integratedDfAM process that considers the functionality and manufacturing of components. Selectedparts of the proposed process are implemented in a case study in order to evaluate theproposed process. In addition, a tool that supports part of the design process is developed. The proposed design process implements Multidisciplinary Design Optimization (MDO) witha parametric CAD model that is evaluated from functional and manufacturing perspectives. Inthe implementation, a structural component is designed using the MDO framework, which includesComputer Aided Engineering (CAE) models for structural evaluation, the calculation ofweight, and how much support material that needs to be added during manufacturing. Thecomponent is optimized for the reduction of weight and minimization of support material,while the stress levels in the component are constrained. The developed tool uses methodsfor high level Parametric CAD modelling to simplify the creation of parametric CAD modelsbased on Topology Optimization (TO) results. The work concludes that the implementation of CAx technologies in the DfAM process enablesa more automated design process with less manual design iterations than traditional DfAM processes.It also discusses and presents directions for further research to achieve a fully automateddesign process for Additive Manufacturing. / AddMan

Over the last decade, Unmanned Aerial Vehicles (UAVs) have experienced an accelerated growth, and nowadays they are being deployed in a variety of missions that have traditionally been covered by manned aircraft. This unprecedented market expansion has created new and unforeseen challenges for the manufacturing industry which is now called to further reduce the idea-to-market times while simultaneously delivering designs of even higher performance. In this environment of uncertainty and risk, it is without a doubt crucial for the involved actors to find ways to secure their strategic advantage, and hence, implementing the latest design tools has become a critical consideration in every Product Development Process (PDP). To this end, a method that has been frequently applied in the PDP and has shown many successful results in the development of complex engineering products is Multidisciplinary Design Optimization (MDO). In general, MDO can bring additional knowledge regarding the best-suited designs much earlier in the process, and in this respect, it can lead to significant cost and time savings by reducing the total number of refinement iterations. Nevertheless, the organizational and cultural integration of MDO has been often overlooked, while at the same time, several technical aspects of the method for UAV design are still at an elementary level. On the whole, research on MDO is showing a slow progress, and to this date, there are many limitations in both the disciplinary models and the available analysis capabilities. In light of the above, this thesis focuses on the particulars of the MDO methodology, and more specifically, on how it can be best adapted and evolved in order to enhance the development process of UAVs. The primary objective is to study the current trends and gaps of the MDO practices in UAV applications, and subsequently to build upon that and explore how these can be included in a roadmap that will be able to serve a guide for newcomers in the field. Compared to other studies, the problem is herein approached from both a technical as well as organizational perspective, and thus, this research not only aims to propose techniques that can lead to better designs but also solutions that will be meaningful to the PDP. Having established the above foundation, this work shows that the traditional MDO frameworks for UAV design have been neglecting several important features, and it elaborates on how those novel elements can be modeled in order to enable a better integration of MDO into the organizational functions. Overall, this thesis presents quantitative and qualitative data which illustrate the effectiveness of the new framework enhancements in the development process of UAVs, and concludes with discussions on the possible improvement directions towards achieving more and better MDO capabilities.

<p>I denna rapport behandlas verktyget FMEA (Failure Mode Effect Analysis), dess användning och genomförande på identifierade komponenter som ingår i elmotorer tillverkade hos ABB LV Motors i Västerås. Målet med detta arbete har varit att ge lärdom om metoden FMEA på företaget för att möjliggöra användandet av verktyget bland medlemmarna på företaget och att vi implementerar verktyget på befintlig motor för att analysera de felsätt som kan uppstå. Eftersom ABB just nu har ett pågående projekt med en ny motor kan våra slutgiltiga felanalyser även ge dem information om vilka ändringar och åtgärder som kan vara till nytta vid utformningen av den nya motorn.</p><p>Efter två veckors praktik i verkstan och en grundlig genomgång av företagets reklamationer kunde vi avgränsa arbetet genom att identifiera de komponenter som analyserna skulle genomföras på. Efter en genomgång tillsammans med våra handledare på företaget kom vi fram till att utföra våra analyser på fem komponenter, två av dem framstod som mycket kritiska som upptäcktes redan vid genomgång av reklamationerna.</p><p>Komponenterna som vi har analyserat är:</p><p>1. Lager</p><p>2. Lindning</p><p>3. Tätning av uttagslåda och uttagslock</p><p>4. Fötter</p><p>5. Sköldar</p><p>Lager som är den näst största kritiska komponent som vi tittat på är en del i motorn som är väldigt känslig, det är viktigt att följa instruktioner för underhåll och smörjning för att undvika för tidiga lagerskador.</p><p>Lindningen är klart den mest kritiska komponenten i våra analyser, detta är för att det är så mycket som spelar in lindningens funktion, koppartrådar, isoleringar, impregnering samt under själva processen kan det uppstå felsätt som påverkar lindningen negativt både direkt men även i ett senare skede då motorn är i drift.</p><p>Tätning av uttagslåda och lock beskriver de felsätt som kan uppstå då tätningen inte är effektiv och tät, vad som kan hända då det kommer in smuts och fukt och hur det eventuellt kan påverka plint eller andra elektriska applikationer. Felanalysen på fötter och sköldar behandlar mycket designfel, toleransfel och hur det påverkar komponenterna.</p><p>I rapporten beskrivs utförligt komponenternas funktioner, processer, underhåll samt det är i princip vad vi har kommit fram till i våra felanalyser fast vi i rapporten beskriver det mer utförligt. Efter beskrivning av varje komponent följer ett FMEA för respektive komponent och de FMEA:n är våra resultat av arbetet, där visas åtskilliga felsätt som är möjliga att uppstå hos varje komponent och även vilka felsätt som är mest kritiska att ta itu med.</p> / <p>In this report we discuss the tool, FMEA (Failure Mode Effect Analysis), we look at its usage and realization on identified components that are included in electrical motors made at ABB LV Motors in Västerås. Our goals with this work have been to give knowledge about the method FMEA to the company so they can learn to use this tool and for us to implement the tool on an existing application to analyze the failures that can occur. Since ABB have a project ongoing with a new motor our analyses can also give them input on what changes and actions to take on the new motor.</p><p>After two weeks training in the workshop and a thorough survey of the companys warranty claims we could define our work by identifying which components we would survey our analyses on. After a run through with our instructors at the company we draw the conclusion to survey our work on five components, which there are two components that are very critical that we discovered during our information collection with the warranty claims.</p><p>The analyzed components are:</p><p>1. Bearing</p><p>2. Winding</p><p>3. Sealing of terminal box and terminal cap.</p><p>4. Motor feet’s</p><p>5. Shields</p><p>Bearing which is after the winding the most critical component, it is a sensitive part and it is very important to follow instructions for maintenance and lubrication to avoid early bearing damages.</p><p>Winding is the clearest most critical component in our analyzes, this is because there is many parts that plays role in the windings function, copper wires, isolations, impregnation and during the process you can have failures that affect the winding in a negative way immediately but also in a later phase when the motor is running.</p><p>Sealing of the terminal box and cap describes those failures that can occur when the sealing is not effective and compact, and what happens is that you get dirt and damp in to the box and how it possibly can affect the connection box and other electrical applications.</p><p>The failure analyze on feets and shields deals with design faults, tolerance faults and how it affects the components.</p><p>In the report we describe the functions of the components, processes, maintenance and that is in general what we have in our FMEA analyses, however in the report we describe it more thoroughly. After the description of every component we have the FMEA of respective component attached. The FMEA analyses are our results in this work, in the analyses we show many possible failures at each component and also which failures are most critical to deal with.</p>

<p>The high level of competition and the rapidly growing technology development has created new challenges for today's businesses where they are forced to deliver more customized products at a lower price and a shorter time period. This places high demands on the companies' ability to design and develop better products in a more efficient way. In addition to developing products, the design process focuses on securing long-term success for the company by developing nourishing skills. However, to achieve an effective design process the companies must improve their ability to plan as well as use their knowledge base in a more efficient manner. Toyota's product development system is a critical component for companies to address challenges that they’re facing and offers a great potential to create significant competitive advantages. Toyota's product development system is designed to streamline the design of processes and products, as they often create restrictions on business and describes the importance of making use of a coordinated effort by several functions, and strives to integrate processes, people, technology and tools in an effective manner.</p><p> </p><p>The concept of Concurrent Engineering includes parallel efforts rather than a time-consuming serial work and seeks to minimize delays in the product development process. Concurrent Engineering enables for quality products, to reach the market faster at a lower cost and allows the company to quickly and flexibly adapt to changing demands and conditions through parallel efforts. Like Toyota’s product development system, Concurrent Engineering promotes an integrated approach where multifunctional teams work towards a common goal striving to solve problems at an early stage.</p><p> </p><p>Propulsion and Control in Västerås, a division within Bombardier Transportation, is currently suffering from extensive engineering changes and struggles to uphold time plans and budgets. The thesis will therefore cover the complete product development process where focus has been directed towards the processes and conditions that could enable for an effective product development process. During the thesis work the underlying causes for the problems mentioned above, have been identified. Internal documents regarding the company's current process has been reviewed and interviews have been carried out in order to evaluate the company’s current situation. During the thesis work a comparative study has been conducted at a large company within the Mälardalen-region. This study has been used as a practical example to reinforce the theoretical reasoning and has additionally allowed for further examination of a company's product development process.</p><p> </p><p>The thesis has resulted in a number of suggestions for improvements, where the main action areas are covered by cross-functionality, routines, follow-up, supplier involvement and prototypes. Another action area that has been identified is front-loading which aims at examining several alternatives and solving problems as well as creating countermeasures at an early stage. These six areas were found to have a significant role in creating an effective product development process and are considered to be relevant for the company's current situation.</p>

<p><strong> </strong></p><p>Detta arbete går ut på att uppfinna och utveckla en enhet som integrerar människor med hjälp av teknik och som ska användas på en konsthall. Prototypframtagning och en optimerad designprocess utmynnar i underlag som ska användas för framställning av denna enhet i större skala. Detta har lösts genom brainfire som generade tre olika koncept. Dessa koncept kombinerades även i ett fjärde koncept som antogs som vinnande koncept efter genomgång av PUGHs beslutsmatris. Konceptet optimerades med hjälp av PU-verktygen DFA, DFM samt DFE. Detta ledde till en monteringsoptimerad, ekonomioptimerad och återvinningsbar enhet. Enheten kläms ihop när användaren vill säga något som ska sparas. Det sagda sparas via radio till ett minne på en klisterlapp. Klisterlappen ges sedan vidare till nästa användare som kan klistra på klisterlappen på en enhet. När enheten då passerar den plats där den förste användaren sparade det denne sade så spelar den upp en spökviskning av det den första användaren sa. På så vis ökar enheten kommunikationen mellan användarna vilket är målet med arbetet. Enheten uppfyller samtliga krav i kravspecifikationen och är återvinningsbar, optimerad för låg energiförbrukning, rengörningsbar, separabel samt innehar lång livslängd i förhållande till dess arbete. Industridesignen upplevs av utomstående som tilltalande, tilldragande, innovativ, futuristisk, intressant, karaktärsrik och ergonomisk.</p>

<p>Saab Aerostructures i Linköping utvecklar och tillverkar flygplansstrukturer. Innan dessa levereras till kund ska de verifieras genom en slutkontroll och vid tiden för denna studie utförs slutkontrollen bland annat i kontrolljiggar. Dessa kontrolljiggar är produkt-specifika och mycket kostsamma att tillverka och underhålla.</p><p>Denna studie behandlar möjligheterna med att införa en mätcell, med tillhörande mät-system, istället för att använda kontrolljiggar för att utföra slutkontrollen. Vid detta införande skulle flera vinster kunna göras. En uppskattning har gjorts av vad det skulle kosta att använda sig av kontrolljiggar i två kommande projekt på företaget och detta har sedan satts i relation till kostnaderna med att investera i ett mätsystem. Vid en sådan investering kan flera intäkter väntas, men dessvärre har dessa övriga intäkter inte kunnat värderats i denna studie. Bland dessa intäkter kan nämnas att fler produkter skulle bli godkända direkt och produktionen underlättas, genom att produktens hela tolerans kan utnyttjas. Med de undersökta mätsystemen kan flexibilitet och mobilitet erhållas till skillnad mot användning av de produktspecifika och fasta kontrolljiggarna. Kontroll- och analysarbetet skulle minska och många förtjänster fås då all mätdata behandlas i datormiljö.</p><p>Vid en eventuell investering i ett nytt mätsystem, rekommenderas en lasertracker med T-Scan från Leica Geosystems. Detta gäller om investeringen kan visas vara lönsam med övriga intäkter inräknade. En beräkning har gjorts som visar att om de övriga intäkterna årligen uppgår till 300 000 SEK, är investeringen återbetald efter tre år.</p> / <p>Saab Aerostructures in Linköping develops and manufactures aero structures. Before these are delivered to the customer they have to be verified through a final control and at the time for this study the final control is performed in a control jig. These control jigs are specific for each product and they are very expensive to manufacture and to maintain.</p><p>This study handles the opportunities with introducing a measuring cell and belonging measuring system, instead of using control jigs to perform the final control. By this introduction several profits could be done. An estimate has been done of what the costs would be of using control jigs in two of the coming projects at the company and then this have been put in relation to the costs of investing in a measuring system. By such an investment several revenues could be expected, but unfortunately it has not been possible to value these in this study. Among these revenues it could be mentioned that more products would directly pass the verification and the production would be facilitated, by being able to use the entire tolerance of the product. With the investigated measuring systems flexibility and mobility can be gotten unlike using the product specific and fixed control jigs. The work with controlling the products and analysing the measuring data would be reduced and there are many good sides to the fact that all handling of measuring data are computer-aided.</p><p>If an investment in a new measuring system is to be made, a Laser Tracker with T-Scan from Leica Geosystems is recommended. That is if the investment can be shown to be profitable with the other revenues taken into account. A calculation has been made which shows that if the other revenues annually total 300 000 SEK, the investment is repaid after three years.</p>

<p>In the assembly process of airframe structures there are many drilled holes and on some parts the holes are mainly drilled manually with pneumatic handheld drilling machines. During conventional drilling in metal, burrs appear. To remove these burrs the parts of the structure must be separated and deburred before they can be put together for fastening. This is a time consuming measure and therefore expensive. To facilitate this process and lower production costs some parts of the process needs to be automated.</p><p>A part of this thesis was a project in co-operation with Saab, Novator, Specma Automation and the University of Linköping. The purpose of this project was to investigate the ability of an industrial robot to drill holes in aeroplane structures using orbital drilling.</p><p>How the project tests were carried out and the results of these tests are presented in the first part of this thesis. The tests showed that slip-stick appeared when a force was applied on the working object by the robot. Because of the movement of the pressure foot the drilled hole will be in the wrong position and if the movement appears during drilling the quality of the hole is being poor.</p><p>Several different tests were performed using different amounts of forces and different pressure feet trying to prevent slip-stick from appearing. Finally tests were performed with good results concerning the quality of the holes.</p><p>In the second part of this thesis the proceeding tests that were carried out are presented. The purpose of these tests was to find out how the robot acts when a static pressure is applied on a work object by the robot and try to find out what the cause of the slip-stick was. Several tests were done where the robot applied a force on several different points on the fixture and the slip-stick was measured.</p><p>The tests that were carried out during this thesis showed that an industrial robot can be used to drill holes in aeroplane structures. To make sure that the quality of the drilled holes is sufficient for the high demands of the aeroplane industry the working area of the robot is limited to a small area in front of the robot. The slip-stick that appears when the robot is extended into a position on the far side of the robot is too large for the robot to drill the hole in an accurate position.</p> / <p>Vid flygplansmontering borras det många olika hål och på vissa delar borras större delen av dessa hål manuellt med pneumatiska handborrmaskiner. Vid konventionell borrning i metall bildas oönskade grader. Strukturen plockas därför isär så att graderna kan tas bort innan strukturens delar kan passas samman igen för att sammanfogas. Detta är en tidskrävande åtgärd och därmed dyr och i ett steg att förenkla denna process och få en billigare produktion vill man automatisera vissa steg i denna process.</p><p>En del av detta examensarbete var ett projekt i samarbete med Saab, Novator, Specma Automation och Linköpings Universitet vars syfte var att klargöra en robots förmåga att borra hål i flygplansmaterial med orbitalborrningsteknik.</p><p>I första delen av detta examensarbete redovisas genomförande och resultat av projektets tester. Testerna visade att tryckfoten gled på testmaterialets yta när roboten lade en tryckkraft på testplåten, så kallad slip-stick uppkom. Denna glidning gör att det borrade hålet inte hamnar på rätt position och sker glidningen under borroperationen så försämras hålets kvalité. Flera olika tester gjordes med varierad tryckkraft och med olika tryckfötter för att försöka förhindra att slip-stick uppkom. Tester genomfördes där hål borrades med bra kvalité.</p><p>I den andra delen av denna rapport redovisas fortsättningen på examensarbetet som var en vidareundersökning av de tidigare genomförda testerna. Syftet med denna del var att undersöka hur en industrirobot beter sig när den används för att lägga på en tryckkraft mot ett material samt att försöka ta reda på vad som är orsaken till slip-sticken. Fler tester gjordes där roboten tryckte på olika punkter på en fixtur och de uppkomna slip-sticken mättes upp.</p><p>Testerna under detta examensarbete har visat att det går att använda en industrirobot till att borra hål i flyglansmaterial. För att kvaliteten på de borrade hålen ska klara de höga krav som ställs inom flygplansindustrin är robotens arbetsområde begränsat till ett litet fönster mitt framför roboten. De glidningar som uppkommer när robotarmen är utsträckt långt åt sidan om roboten är alldeles för stora för de positioneringskrav som är på hålens placering på flygplansstrukturen.</p>

<p>Detta examensarbete är utfört vid institutionen för ekonomisk och industriell utveckling, IEI, vid Linköpings tekniska högskola, för CH Industry i Eskilstuna. Syftet med arbetet är att kartlägga de för företaget viktigaste artiklarna genom identifiering av tillverkningsflöden samt fastställa beläggningsgraden för respektive maskinresurs. Arbetet avgränsas till att endast identifiera tillverkningsflöden för totalt 40 artiklar. Den mest betydande artikeln för CH Industry analyseras med hjälp av en värdeflödeskarta för identifiering av produktionsförloppet, informationsflöden samt av tider i mellanlager.</p><p> </p><p>Arbetet är uppdelat i sex delar. Första hälften beskriver verksamheten för företaget samt teorin bakom begrepp och termer som används i arbetet. Därefter förklaras hur arbetet har utförts och resultat presenteras. I den avslutande delen av arbetet behandlas slutsatser följt av en diskussion kring dessa.</p><p> </p><p>Arbetet resulterade i ett omfattande Excelarbete där tillverkningsflödena är kartlagda och data om operationstider, ställtider samt beläggningsgrader för maskinresurserna är identifierade. Från kartläggningen av tillverkningsflödena identifierades maskinresurser som ur ett flödes- och transportperspektiv är felplacerade. Stora delar av detaljerna flödar från blästerresurs 20 till fleroperationsresurs 57 och därefter vidare till färdigvarulager. Till blästerresurs 20 anländer mer än hälften av alla bearbetade detaljer från resursgrupp ”Ämne” (laserskärare, stans och kap).</p><p>Genom att strategiskt flytta blästerresurs 20 och fleroperation 57 närmare varandra kan transportsträckor, mellanlager samt ledtider minskas. Området kring den gamla laserskärningsparken är passande för ändamålet.</p><p>Pelarborrarna i fleroperationsresurs 56 kan omfördelas till manuell svetsgrupp samt manuell bockningsgrupp. Operatörerna i dessa resursgrupper kan därmed själva utföra brotschning samt borrning av mindre tillverkningskvantiteter innan bock- eller svetsoperationen. Detta skulle medföra en eliminering av mellanlager både före och efter fleroperationsresursen samt minskning av transportsträckor.    </p><p> </p><p>Värdeflödeskartan visar på att den analyserade artikeln överproduceras. Artikeln tillverkas i allt för stora kvantiteter vilket medför lång tid i mellanlager samt onödig hantering. Genom att tillverka artikeln efter kundens behov minskar ledtiden samt kapitalbindningen i lager.</p> / <p>This bachelor thesis has been conducted at the Department of Management and Engineering, IEI, at the University of Linköping, for CH Industry in Eskilstuna. The purpose of this report is to map the most crucial products of the company by identifying the value stream and measuring the capacity utilisation for relevant machines. The report is limited to the analysis of the production flow of a total of 40 products. The most significant products for CH Industry are analysed by means of a value stream map for identification of the production process, the information flow and times in stockpiles.   <strong></strong></p><p>The report is divided into six parts. The first half of the report describes the corporate enterprise of CH Industry, presents the theory behind the concept and also explains the methods used in the report. The second half describes how the analyses were carried out and the results are presented.  The final chapter contains a conclusion followed by a discussion.</p><p>The report results in an extensive Excel document where the value stream is mapped and information about operation times, changeovers and capacity utilisation for the machine resources are identified. The mapping of the value stream reveals machine resources that from both a material flow and a transporting perspective are misplaced. Large sections of the details flow from blast resource 20 to milling machine recourse 57 and after that to the final inventory of goods. To the blast resource 20, more than half of the processed details come from the resource group ”Ämne” (laser cutter, stamping machine and cut-off saw).</p><p>Strategically moving blast resource 20 and milling recourse 57 closer to each other would reduce transport distances, storage and lead times. The area where the old laser-cutting park was located would be suitable for this purpose.</p><p>The pillar drills in the multi-operation resource 56 could be rearranged to a manual welding group and a manual bending press group. The operators for these resource groups could then do the broaching or drilling operation for smaller quantities before the actual bending or welding operation. This would eliminate stockpiles before and after the multi-operation resource and would reduce transport distances. </p><p>The value stream map indicates that the analysed article is overproduced. The article is manufactured in big quantities, which leads to long time in stockpiles and unnecessary handling. By manufacturing the article on customer’s demand lead times and capital tied up in stockpiles could be reduced.</p>