Táto diplomová práca popisuje optimizáciu obrábacieho procesu za účelom zvýšenia produktivity výrobnej linky. Zadanie bolo vypracované v priebehu priemyselnej stáže vo firme Stellantis na obábacej linke blokov valcov motoru DV. Práca vysvetľuje metódy analýzy strát produktivity na výrobnej linke a aplikácii opatrení smerujúcich ku zvýšeniu produktivity, obzvlásť nasadenie nástrojov štíhlej výroby. Najviac boli nasadené nástroje SMED, ktorého cieľom je optimizácia výmeny rezných nástrojov, a TPM, ktorý ma za cieľ zvýšiť spoľahlivosť výrobných prostriedkov.

This thesis deals with examination of the efficiency of the use of the selected machine in the company HARTMANN – RICO, and presents proposals of its increase through lean production methods. The introductory section offers a description of the company's business activities. The theoretical part summarizes the most important findings and methods of lean production. The analytical part examines the machine in terms of production process and subsequently offers an analysis of the current state conducted in order to find bottlenecks in production. The practical part presents proposals of lean production methods implementation with the purpose of increasing the efficiency of the machine.

Detta examensarbete utfördes inom högskoleingenjörsprogrammet i maskinteknik påKarlstads universitet. Projektet var i samarbete med PLS Produkter AB i Skövde där omställningen på en maskin med namnet Tretapparen analyserades. Maskinen klassas somen multitasking maskin där syftet är tappning av olika typer av flaskor. Problemet är att detsker omställningar ofta då maskinen är flexibel och kan producera många olika typer avprodukter. Omställningarna sker då en ny produkttyp ska tillverkas och är väldigttidskrävande då nya inställningar på maskinen behöver göras. Maskinen och verktygenbehöver dessutom rengöras noga för att inte kontaminera nästa batch. Examensarbetets syfteär att effektivisera omställningen genom att tydliggöra omställningstiderna för maskinensolika moment och bidra med kultur- och kunskapsbyggande till företaget. Målet är att hittamöjliga lösningar som minskar ställtiden på de moment som tar längst tid att ställa om ochdär det kan antas finnas förbättringsmöjligheter. Därmed kan flödet på maskinen förbättras iden mån att antalet tillverkade produkter ökar. Förbättringsarbetet började med förstudier, intervjuer, datainsamlingar och att analyseravideos. All viktig information sammanställdes i en A3-modell där SMED var grunden förstrategierna som gjordes för att ställtidsreducera. Resultatet innebär en konvertering från intern till extern ställtid för varje moment var för sigefter respektive färdig omställning, 26 förbättringsförslag och en ny ordning föromställningsarbetet som tillsammans effektiviserar, standardiserar och planerar upp omställningsprocessen. Efter förändringen minskade omställningstiden med totalt 30%, vilket leder till att flödet påmaskinen förbättras då maskinen kan producera ungefär 217 produkter mer än i dagsläget. Islutet av arbetet gjordes en avrapportering till företaget där samtliga produktionsteam varnärvarande. / This degree project was carried out within the university engineering program in mechanicalengineering at Karlstad University. The project was in collaboration with PLS Produkter AB in Skövde, where the conversion on a machine called Tretapparen was analyzed. The machineis classified as a multitasking machine where the purpose is bottling different types of bottles.The problem is that there are changes often as the machine is flexible and can produce manydifferent types of products. The adjustments take place when a new product type is to bemanufactured and are very time-consuming as new settings on the machine need to be made.The machine and tools also need to be cleaned thoroughly so they do not contaminate thenext batch. The purpose of the degree project is to streamline the adjustment by clarifying theadjustment times for the machine's various steps and contributing cultural and knowledgebuilding to the company. The goal is to find possible solutions that reduce the set-up time onthe steps that take the longest time to adjust and where it can be assumed that there areopportunities for improvement. Thus, the flow on the machine can be improved to the extentthat the number of manufactured products increases. The improvement work began with feasibility studies, interviews, data collection andanalyzing videos. All important information was compiled in an A3-model where SMED wasthe basis for the strategies made to reduce downtime. The result implies conversion from internal to external set-up time for each step separatelyafter each completed conversion, 26 improvement proposals and a new arrangement for theconversion work that together streamlines, standardizes and plans the conversion process. After these changes, the adjustment time decreased by a total of 30%, which leads to animprovement in the flow on the machine as the machine can produce approximately 217products more than at present. At the end of the work, a report was made to the companywhere all production teams were present.

The report describes a field study conducted at an enterprise, where the company's machine manufacturing was examined with the aim of reviewing current production capacity and presenting theoretical improvement measures using production engineering methods.  Various work measurements revealed problematic work practices that were unnecessarily time-consuming, where setup times were highlighted as a cause. Time and frequency studies were conducted to clarify the work process and thus the potential for improvement. A SMED analysis was performed to reduce setup times and create manufacturing capacity. The study clarified a work process with a strong lack of setup routines and work standards.  The report proposes a standardized work process as well as a reduction in setup time during setup, in addition to underlying causes of capacity losses resulting from, among other things, poor supervision and material handling.  Overall, the work is considered to have high reliability and validity thanks to the use of industry-tested methods that have generated several improvement measures.

In a global market, the competition is strong and companies are competing against each other all the time. By obtaining competitive advantages such as flexible production, short delivery times, quality and low prices, a company can attract major customers and create major advantages compared to their competatives.   Kongsberg Automotive AB is a global company operating in the automotive industry and distributing goods to several famous brands. Due to high demands from clients, Kongsberg is working with continuous improvement which helps the company to develop and improve their effectiveness. One problem the company has had under observation for a while is their setup process. The setup process has not had a major change since 1996 when the company introduced a workstation that prepares tools for the production. The company has decided to investigate further into the setup process to see which improvements are possible to carry out the setup process. The investigation covered the setup time reduction through an analysis made by using the SMED-method in the program AviX SMED.   AviX SMED uses video-recorded material were the most representative setup was used as an object. The program offers the possibility to analyze the video-recorded material using categorizations and by splitting up the various elements of the set of workers available. SMED is an elaborate method of setup time reduction which comes from Japan in the 1950´s and follows a number of different steps that should be taken in order to get the desired results.   The investigation resulted in several suggestions for improvement where two different proposals for action was developed. The proposed actions were developed with a main focus on "with investments" and "without investment". The proposal without invesments was used as suggested actions to Kongsberg because investments were not the focus. The ”non investment”-suggestion reduced setup time on average by 29 % in four of the analysed setups. Kongsberg can continue to reduce setup time by technical efficiency but that requires more profound analysis of how complex features work and interact with each other.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The contribution of the metalworking sector to the gross domestic product is decreased by 8.6% in the 2017–2018 period because of problems such as high rejection rates, lead times, and raw material losses. Consequently, the sector’s production was reduced by PEN 1,200,000 while demand remained flat. Thus, this article proposes a production control model using 5S, Single-Minute Exchange of Dies, and tools such as Kanban and Constant Work-in-Progress (CONWIP) to increase the productivity of a sand casting line in a Peruvian metalworking enterprise that manufactures parts for mining on request. The improvement proposal involves the implementation of lean manufacturing tools and analyzes low productivity effects. The problems identified are typical of the Peruvian metalworking sector; thus, this study may contribute to finding possible solutions for issues faced by other enterprises. / Revisión por pares

The thesis developed in the field of study Electrical Manufacturing and Management is aimed at optimizing and streamlining of production plastics vacuum forming plastics technology rolled in a particular company. The theoretical part focused on the description of the principles of industrial engineering and survey methods that are fundamentals of lean manufacturing or the Toyota production system. The larger part is devoted to methods of 5S and SMED. The practical part of the optimization steps are designed to ensure increased production, balanced production and increase quality, which are based primarily on methods of 5S and SMED. To complement the work given the changes in production processes resulting from other methods of industrial engineering. Several proposals have been practically applied in the production are assessed and their benefits.

Producerande företag har utvecklats enormt de senaste decennierna. Det har gåttfrån att vara ett lokalt sågverk till att använda högteknologiska robotar.Globaliseringen har gjort att konkurrenssituationen blivit allt mer komplex ochsträng. Stora producerande företag kan verka konkurrenskraftigt globalt och dettaleder till att ännu större krav ställs på de lite mindre företagen, för att de ska hanågon chans att träda in på marknaden. Eftersom produktiviteten för producerandeföretag hela tiden ökar. För lönsamhet krävs därför ett ännu större fokus påeffektivitet och eliminering av slöserier. Därför valdes undersökningsfrågan:Hur kan produktionsprocesserna och värdeflödet ef ektiviseras på ett producerandeSME-företag?Syftet med fallstudien är att öka förståelsen för hur producerande företag kaneffektiviseras genom att bland annat kartlägga nuläget och utföra envärdeflödesanalys. Som hjälpmedel kommer olika lean-production verktyg kommatill användning för att öka effektiviteten och eliminera slöserier.För att kunna ge ett omfattande svar på undersökningsfrågan har en analysmodelllegat som grund för studien. Analysmodellen har gjort planeringen av fallstudienmer konkret. Analysmodellen består av fyra faser och den första fasen är att samlain data i olika former. Den andra fasen är att beskriva den nuvarande situationenproduktionsprocesserna har, med hjälp av den insamlade datan för att senare kunnautforma en värdeflödesanalys. Den tredje fasen är att identifiera olika typer avslöserier genom att kartlägga nuläget. Fas fyra är förbättringsförslag på hur man kaneliminera dessa slöserier och ge en mer effektiv framtida produktion. Den förstafasen har genomförts genom att samla in befintlig teori för att ha något att utgå ifrånoch jämföra med. Kartläggningen av nuläget som är väsentlig för fallstudienutformades genom observationer, tidsmätningar och intervjuer för varje enskildprocess. Den empiriska informationen jämfördes med den teoretiska insamladeteorin och olikheter dokumenterades. Detta ledde till att slöserier kunde identifierastill stor del med hjälp av olika lean verktyg. En värdeflödesanalys utfördes för attdela in den tillgängliga tiden i värdeskapande tid och icke värdeskapande tid för attkunna rangordna vilken process som är i mest behov av förbättring.Resultatet som analysmodellen har presenterat är att fallföretaget bör implementeraSMED, 5S, underhållsarbete och mer dokumentering för att ständigt kunnaförbättras. Efter att fallföretaget har implementerat dessa lean verktyg och detfungerar bra i praktiken finns det utrymme för ytterligare förbättringsmöjligheter.Bland annat genom att använda sig av ett dragande system istället för ett tryckandeoch på så sätt göra sig av med flertalet lager. Alla dessa metoder skulle leda till attfallföretaget blir mer konkurrenskraftiga.

El consumo de aguas envasadas ha experimentado un gran aumento desde el 2013. La industria del agua embotellada, actualmente, está presente en la mayoría de las principales ciudades del país, es un producto de consumo masivo e indispensable para las actividades diarias de la población. De tal manera, en el Perú las plantas de tratamiento de agua en el sector de Pyme presentan una baja eficiencia operacional en sus líneas de producción. Este problema genera incumplimientos en las entregas de los pedidos, lo cual representa pérdidas económicas que bordea alrededor de un 15% de sus ventas anuales, esto se debe a que se incurre en tiempos improductivos y la falta de mantenimiento necesarios. Por lo tanto, este estudio desarrolló un modelo que permitirá aumentar la eficiencia en planta mediante la aplicación de la herramienta SMED y mantenimiento autónomo que reducirá tiempos de set up y averías respectivamente. El modelo propuesto tiene como objetivo reducir los tiempos de set up hasta en un 36%, mientras que para el tiempo de paradas por averías hasta un 60%, alcanzando así un porcentaje superior al 80% de eficiencia en planta (OEE). / The consumption of bottled water has experienced a great increase since 2013. The bottled water industry, currently, is present in most of the main cities of the country, it is a product of massive consumption and indispensable for the daily activities of the population. Thus, in Peru, water treatment plants in the SME sector have low operational efficiency in their production lines. This problem generates defaults in the deliveries of the orders, which represents economic losses that border around 15% of their annual sales, this is due to the fact that they incur in downtime and the lack of necessary maintenance. Therefore, this study developed a model that will increase plant efficiency through the application of the SMED tool and autonomous maintenance that will reduce set-up times and breakdowns, respectively. The proposed model aims to reduce set up times by up to 36%, while for breakdown time by up to 60%, thus reaching a percentage greater than 80% in-plant efficiency (OEE). / Trabajo de investigación

This is a master thesis done in the program of industrial design engineering at Luleå University ofTechnology, conducted during the spring of 2021. The project is a collaboration with Epiroc RockDrills AB which is a leading global company in the mining industries, and the workshop in which thisthesis is made manufactures and assembles rock drills sold worldwide. The aim of this thesis is toincrease the utilization of three lathes in the workshop that are often left unused when theiroperators have to leave the machines to perform other tasks. This is due to short operation timesthat require the operator to be present.The project follows a cyclic method in order to force the work forward without worrying aboutmissing information. There were three cycles with different aim. In the first cycle, the focus was onplanning the project and mapping the current state. In the second, a requirement specification wasmade and concepts were created. These concepts were further developed in the third cycle. Finally arecommendation was made.The current state was mapped using different methods like interviews and spaghetti diagram. Thesemethods showed that the lathes were unused mainly during setups, and that setups were timeconsuming due to equipment being placed far away from the lathes. The result showed that manyproblems could be related to bad layout design and lack of standardized work. In order to create abetter layout for the operators, a relationship chart was made and several suggestions constructedbased on it. The purpose of the layout changes was to get necessary equipment closer to the lathesin order for the setups to be performed faster. All suggestions were compared to the requirementspecification and only three were further developed during the third cycle.The lean tool SMED (Single Minute Exchange of Die) was used to create a standard for setups. Thisstandard was further developed into a work instruction to be better visualized for the operators.The final recommendation is to make layout changes according to one of the layouts presented inthis report, and to implement the work instruction. These changes will increase the utilization bypreparing as much as possible before the lathe is tuned off.