Detta examensarbete utfördes på Otis AB, en global tillverkare och underhållare av hissar, rulltrappor och rullband. Arbetet behandlar företagets reservdelshantering och de processer och rutiner som följer av denna. Otis genomförde under hösten 2010 en storskalig kundundersökning som visade att företaget inte lever upp till uppsatta mål rörande kundtillfredsställelse. Företaget har i sin strävan att öka kundernas tillfredställelse insett att en ökning av leveransservicen, den service ett företag kan erbjuda sina kunder vid leverans av varor och tjänster, är nödvändig. Detta är något som företaget tror kan uppnås genom en förändring av den nuvarande reservdelshanteringen. Examensarbetets huvudmål är således att genom att utforma en ny kostnadseffektiv reservdelshantering uppnå en ökning av den leveransservice som Otis kan erbjuda sina kunder. Det underlag som krävdes för utvecklandet av denna rapport har till viss del inhämtats från intervjuer och möten med personer anställda vid Otis Stockholmskontor i Solna. Ett annat viktigt underlag för studien är den statistiska information som gått att inhämta från Otis samt dess huvudsakliga underleverantörer rörande företagets verksamhet. Vidare har utförliga empiriska studier utförts kring de aktiviteter som ingår i företagets nuvarande reservdelshantering. Som ett komplement till dessa studier har passande litteratur använts, litteratur som ligger till grund för både de praktiska och teoretiska studierna. Analysen resulterade i två alternativa logistiska strukturer för företaget. Dessa alternativa logistikstrukturer utvärderades utifrån leveransservice samt kostnadskonsekvenser för att i slutändan kunna jämföras med varandra samt med det nuvarande logistiksystemet. Det ena alternativet består av en intern lagerföring av reservdelar i företagets lagerlokaler i Solna samt Älvsjö medan det andra består av en intern lagerföring av reservdelar i hissmontörernas servicebilar. Av dessa alternativ rekommenderar vi Otis att implementera lagerföring av reservdelar i hissmontörernas servicebilar. Båda de framarbetade logistikalternativen resulterar i en ökning av Otis leveransservicenivå samt i reducerade logistikkostnader jämfört med dagens situation. Båda alternativen har potential att uppnå en liknande leveransservicenivå men där en lägre totalkostnad kan uppnås vid lagerföring i hissmontörernas servicebilar. Detta i kombination med att den övergripande strategin inom organisationen underlättar för en implementering av alternativet med lagerföring av reservdelar i hissmontörernas servicebilar har legat till grund för vår rekommendation. / This thesis was conducted at Otis AB, a global manufacturer and service provider of elevators, escalators and travelators. The thesis deals with the company's spare part handling and the processes and procedures resulting from this. Otis conducted in the autumn of 2010 a large-scale customer survey which showed that the company did not live up to set targets concerning customer satisfaction. The company has in its struggle to increase customer satisfaction realized that an increase in delivery service, the service a company can offer its customers upon delivery of goods and services, is necessary. This is something that the company believes can be achieved by a change in the present spare part handling. The thesis main objective is therefore to design a new cost-effective spare part handling to achieve an increase in the delivery service that Otis can offer its customers. The material required for the development of this report has partially been collected from interviews and meetings with employees at Otis office in Stockholm. Another important basis for the study is the statistical information that has been obtained from the company and its main subcontractors. Moreover, detailed empirical studies have been conducted around the activities involved in the present spare part handling. To complement these studies suitable literature has been used as the basis for both the practical and theoretical studies. The analysis resulted in two alternative logistics structures for the company. These logistics structures were evaluated based on delivery service and cost implications to ultimately be compared with each other and with the existing logistic system. The first alternative consists of internal holding of spare parts in the company's warehouses in Solna and Älvsjö while the second consists of internal holding of spare parts in the elevator mechanics’ service cars. Of these alternatives, we recommend Otis to hold spare parts in the service cars. Both logistics alternatives result in an increase of Otis delivery service and in reduced logistics costs compared to today's situation. The alternatives have the potential to achieve similar delivery service but a lower total cost can be achieved by holding spare parts in the mechanics’ service cars. This fact, combined with an overall strategy of the organization that facilitates an implementation of the alternative consisting of holding spare parts in the mechanics’ service cars have been the basis for our recommendation.

Detta är en studie om hur en framtagning utav en transportlåda på företaget AstraZeneca utfördes. Syftet med studien var att transportlådan skulle ersätta tre olika transportlådor som användes för att paketera tre olika storlekar på en förpackning som innehåller samma produkt. Förpackningarna har samma höjd och bredd men har olika längdmått beroende på hur många produkter som ska in i samma förpackning. Den första förpackningen har 1 produkt i sig, den andra förpackningen har 2 produkter i sig och den tredje förpackningen har 3 produkter i sig. För att ta sig an problemet användes linjärprogrammering för att hitta största gemensamma längdmått som ligger inom dimensionerna för en standardiserad EUR-pall. Utöver framtagningen utav lådan utfördes en flödesanalys samt en kostnadsanalys för att hitta förbättringsområden och kostnadsreduceringar i flödet. Studien lyckades att ta fram en låda där all tre olika förpackningar fick plats i och utöver det medförde den framtagna lådan att antalet produkter på pall ökade med 20% för förpackningen med 1 produkt i sig, 12 % för förpackningen med 2 produkter i sig och den sista förpackningen har samma antal produkter på pall jämfört med föregående låda. Kostnadsanalysen visade en kostnadsreducering på 1,96 mkr per år på inköpspriset jämfört med inköpskostnader för de tre tidigare transportlådorna. Slutsatsen för denna studie blev därför att det är en förbättring att införa den framtagna lådan istället för att ha tre separata transportlådor för respektive förpackning. / This is a study to display the process of developing a transportation box for the pharmaceutical company AstraZeneca. The purpose of study is to develop a transportation box in such a way so it could replace three already existing transportation boxes and enable these products to use the same transportation box. The products contain the same pharmaceutical product but has different dimensions for their respective containers where the height and the width is the same on all containers but has different length measurements depending on the number of pharmaceutical products in them. The first container contains 1 product, the second container contains 2 products and the third container contains 3 products. The solution to this problem was to use linear programming to establish a common length that the three containers share but is not larger than the dimensions on a standard EUR-pallet. Furthermore, the study was using a valueflow analysis and a cost analysis to determine which areas this transportation box can improve different processes within the company’s material flow. The linear programming succeeded in finding a common length for the three containers and a prototype was constructed in collaboration with the supplier. With the developed transportation box the study managed to increase the quantity on each pallet for 2 out of the 3 containers. The first container increased the quantity for each pallet with 20% and the increased the quantity for the second container with 12%. The quantity for the third container on each pallet remained the same as before. Furthermore, the cost analysis showed a reduced cost for purchasing the transportation box by 1,96 million SEK. This number is a comparison of the cost for the three already existing transportation boxes and an estimated prize on the developed transportation box. The verdict for this study is to implement the developed box because of the reduced costs and the improvements in the material flow that the box provides.

This report is the result of a 20-points project at the University of Jönköping. The project was carried out in form of a case study with the object of analysing the value flow at DIAB AB’s confection department in Laholm. The aim of this project is to submit proposals to the production management on how to increase the efficiency of the production flow at the confection department and reduce the capital accumulation in form of products in work. The information in this report is gathered from interviews, observations and measurements. Furthermore, a literature study was carried out in view to find suitable theories when analysing present as well as future suggested production conditions. This report is based on four main questions: • What does the existing process of the value flow for the most produced product family look like? • How does the process of the value flow for GS perform considering the through-put-time? o How long through-put-time does a representative product of the GS-family have? o How long is the value- and no value adding time for that product along its production flow? • Which production related disturbances and cost prompters exist in the present value flow process? • How could the process of the value flow for GS be made more efficient, less persistent to disturbances and more competitive? The existing process of the value flow for the most producing product family has been mapped and is illustrated in appendix 3. For now, the process includes nine working stations along the production chain. The through-put-time of a representative GS-product is according to my survey 18,5 days. The value adding time is only 16,1 minutes, that is 0,061 % of the entire through-put-time. The remaining time, in other words the no value adding time, is 440 hours and it represents mainly storage and transport of products. The representative production disturbances and cost prompters that characterise the process of the value flow contain material related disturbances, a high number of long shifts, long storage time prior to the customer order point and with that, high capital accumulation and finally unnecessary transports. Improvement proposals aim to increase the efficacy of the process of the value flow and reduce the capital amounts by shifting from the present production strategy involving manufacturing towards order (TMO) to assembling towards order (MMO). In order to make this possible a semi-manufactured storage will be introduced after the standard confection which will represent the new decoupling point. The production at the standard confection will then occur according to the semi-manufactured storage. The standard confection should produce in larger aggregated order quantities based on prognosis in order to benefit from the advantages of economy of scale and the production must proceed in a continuous flow according to the FIFU-system (First In First Out). In addition to that, the special confection must produce according to a pull-system and only when the customer makes a request. The tact-time of the GS products should constitute a limit for all the cycle times along the production chain, both on the standard- and special confection. This is partly due to creating a constant and balanced production flow which enables short through-put-time and partly due to avoiding in-between-storage as a result of various bottlenecks.

<p>This report is the result of a 20-points project at the University of Jönköping. The project was carried out in form of a case study with the object of analysing the value flow at DIAB AB’s confection department in Laholm. The aim of this project is to submit proposals to the production management on how to increase the efficiency of the production flow at the confection department and reduce the capital accumulation in form of products in work.</p><p>The information in this report is gathered from interviews, observations and measurements. Furthermore, a literature study was carried out in view to find suitable theories when analysing present as well as future suggested production conditions.</p><p>This report is based on four main questions:</p><p>• What does the existing process of the value flow for the most produced product family look like?</p><p>• How does the process of the value flow for GS perform considering the through-put-time?</p><p>o How long through-put-time does a representative product of the GS-family have?</p><p>o How long is the value- and no value adding time for that product along its production flow?</p><p>• Which production related disturbances and cost prompters exist in the present value flow process?</p><p>• How could the process of the value flow for GS be made more efficient, less persistent to disturbances and more competitive?</p><p>The existing process of the value flow for the most producing product family has been mapped and is illustrated in appendix 3. For now, the process includes nine working stations along the production chain.</p><p>The through-put-time of a representative GS-product is according to my survey 18,5 days. The value adding time is only 16,1 minutes, that is 0,061 % of the entire through-put-time. The remaining time, in other words the no value adding time, is 440 hours and it represents mainly storage and transport of products.</p><p>The representative production disturbances and cost prompters that characterise the process of the value flow contain material related disturbances, a high number of long shifts, long storage time prior to the customer order point and with that, high capital accumulation and finally unnecessary transports.</p><p>Improvement proposals aim to increase the efficacy of the process of the value flow and reduce the capital amounts by shifting from the present production strategy involving manufacturing towards order (TMO) to assembling towards order (MMO).</p><p>In order to make this possible a semi-manufactured storage will be introduced after the standard confection which will represent the new decoupling point. The production at the standard confection will then occur according to the semi-manufactured storage. The standard confection should produce in larger aggregated order quantities based on prognosis in order to benefit from the advantages of economy of scale and the production must proceed in a continuous flow according to the FIFU-system (First In First Out). In addition to that, the special confection must produce according to a pull-system and only when the customer makes a request.</p><p>The tact-time of the GS products should constitute a limit for all the cycle times along the production chain, both on the standard- and special confection. This is partly due to creating a constant and balanced production flow which enables short through-put-time and partly due to avoiding in-between-storage as a result of various bottlenecks.</p>

Högre krav ställs på effektivitet och optimering av flödet hos distribuerande företag för att kunna möta det ökade antalet varor som hanteras. För att möta detta krav krävs ledtidsreducering i form av att minska icke värdeskapande tid samt att fokusera på arbetsmiljö för medarbetarna, i form av ergonomi. Ett stort fokus ligger även på att tillfredsställa kund i form av att leverera rätt kvalitet i rätt tid. Syftet med arbetet är att få en förståelse för effektiviseringsmöjligheter inom lagerhantering på ett distribuerande företag och utveckla ett arbetssätt som minskar ledtiden och förbättrar arbetsmiljön med fokus på ergonomi. Målet med studien är att ta fram ett effektivare arbetssätt i form av minskad ledtid och bättre arbetsmiljö, där fokus är ergonomi. Frågeställningar som tagits fram för att uppnå syftet berör hur ett distribuerande företag kan hantera lager på ett effektivare sätt i form av minskad ledtid samt hur lagerhanteringen kan förbättras med avseende på arbetsmiljön och dess ergonomiska aspekter. En värdeflödesanalys har tagits fram baserat på observationer och mätningar. I värdeflödesanalysen framgick det att processerna för inregistrering av paket och plock av paket hade förbättringsmöjligheter. Tester har utförts för att undersöka om olika förbättringsförslag medfört minskad ledtid och förbättrad arbetsmiljö i form av ergonomi. Resultatet visar att ett nytt arbetssätt tillsammans med en ny layout minskar ledtiden samtidigt som arbetsmiljön förbättras då personalen rör sig mindre. Slutsatsen är att ett effektivare och mer ergonomiskt arbetssätt gynnar företaget, medarbetare och kunder. / Higher demands are placed on efficiency and optimization of the flow of distribution centers due to the higher amount of products they are handling. To meet this requirement, lead time reduction is required to reduce non-value-adding time and focus on the work environment for a better ergonomics. Another important thing is to satisfy the customer in order to deliver the right quality on the right time. The purpose of the work is to gain an understanding of efficiency opportunities in warehouse management at a distributing company and to develop a working method that reduces lead time and improves the work environment with a focus on ergonomics. The aim of the study is to develop a more efficient way of working to reduce lead time and develop a better work environment, where the focus is on ergonomics. Issues that were developed to achieve the purpose of this case study concern how a distribution company can handle inventory in a more efficient way in the form of reduced lead time and how inventory management can be improved regarding work environment and ergonomic aspects. A value flow analysis was created based on observations and measurements. The value flow analysis showed that two different processes had opportunities for improvement. Tests have been performed to investigate if different improvements could reduce lead time and improve the work environment. The results showed that a new way of working together with a new layout reduced lead time. The conclusion shows that a more efficient and ergonomic way of working benefits the company, the employees, and the customer.