Passenger vehicles are central to Western society, and contribute to a significant part of our greenhouse gas emissions. In order to reduce emissions, the automotive industry as a whole is working to reduce mass in passenger vehicles in order to reduce energy consumption. One way to reduce mass is to introduce lightweight materials in the body of the vehicle. This research aims to explore the relationship between product and production system when introducing new materials. Besides a theoretical review and an industry-centered technological mapping, four case studies have been conducted during the course of this licentiate thesis. Two case studies were conducted with engineering design students working as development teams, one case study with the author as the developer and finally one case study in an industrial environment at a product owning company with in-house production. The goal of the case studies has been to increase the collective knowledge of how product development decisions affect production development decisions, and vice versa, when developing passenger vehicles in new materials. In the following analysis of case study outcomes, a number of factors important for introducing new materials are discussed. The relationship between product and production is investigated, both in terms of how the production system affects the product and how the product affects the production system. The outcome from this analysis is a mapping of important factors for automotive industry companies to understand and identify when looking at introducing new materials in existing production systems. Finally, a suggestion for future research efforts is presented.

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Examensarbetet genomfördes på AB Furhoffs Rostfria som grundades år 1899. Företaget är lokaliserat i Skövde och har 150 anställda. AB Furhoffs Rostfria tillverkar produkter i rostfritt stål, både för egentillverkning och för legotillverkning. Produktionen består av tre produktflöden: lego, VVS, och RFI. I examensarbetet har instrumentfrontar som ingår i lego-flödet och diskbänkar som ingår i RFI-flödet analyserats vid genomförandet av datainsamlingen. Med anledningen att slipdamm bildas vid slipning av produkterna är slipstationerna placerade i ett enskilt rum i produktionen. Företaget uppfattar att rummet är onödigt stort och därför är syftet med detta projekt att ta fram en ny layout över sliprummet där den använda ytan för sliprummet har minskats. I fallstudien undersöktes relevanta teorier och litteraturstudier för att hitta användbara metoder och verktyg samt för att skapa underlag till utförandet av arbetet. Genomförandet av nulägesanalysen av sliprummet utfördes genom att använda observationer utifrån gemba, kvalitativa intervjuer, spagettidiagram på sliparbetarnas rörelser vid arbetet på instrumentfrontarna och diskbänkarna samt VSM-kartor tillsammans med tidsstudier utifrån den Kontinuerliga metoden. Analys av 5S och ergonomi genomfördes också för att hitta brister som företaget kan förbättra om de väljer att implementera det slutliga layoutförslaget. Den dokumenterade data över nulägesanalysen användes vid framtagningen av det slutliga layoutförslaget. Framtagningen av layoutförslagen gjordes utifrån lokalplanläggningsmetoden. I projektet togs fem layoutförslag fram, som relevant personal fick granska och ge feedback på, vilket resulterade i ett slutligt layoutförslag. Det slutliga layoutförslaget som togs fram frigjorde yta både inne i sliprummet och utanför på totalt 38m2, vilket är yta som företaget kan använda till att vidareutveckla produktionen. Med det slutliga layoutförslaget har onödiga rörelser minskats, där RFI-inplats kommit närmare station 1 och 3 som arbetar med produkter från RFI-flödet. Datorn som operatörerna stämplar in på för varje order har även flyttats till en centralare position i sliprummet, för att minska operatörernas onödiga rörelser. Om flera av samma produkttyp ska slipas, stämplar sliparbetarna i dagsläget in alla produkter samtidigt i datorn. Genom att ha minskat avståndet från stationerna till datorn och till inplatserna, är förhoppningarna att operatörerna slutar med att stämpla in flera produkter samtidigt, vilket ska leda till att företaget får korrektare tider för utförandet av arbetet. / This bachelor thesis was carried out at AB Furhoffs Rostfria, which was founded in 1899. The company is located in Skövde and has 150 employees. AB Furhoffs Rostfria produces products in stainless steel. The company produces their own products and products for other manufacturing companies. The production consists of three product flows: lego, VVS and RFI. In this bachelor thesis, instrument fronts which are included in the lego-flow and sinks that are included in the RFI-flow, were analyzed during the implementation of the data collection. When grinding, dust is created as a byproduct and therefore have the grinding stations been placed in a separate room in the production. The company has the opinion that this room is unnecessary large and therefore is the aim of this project to create a new layout for the grinding room, where the used space in the grinding room has been decreased. In this case study relevant theories and literature studies were analyzed to find useful methods and tools to create a base for the execution of the project. The analyze of the current situation in the grinding room was done through observations using gemba, qualitative interviews, spaghetti diagram of the grinding workers' moment when working on the instrument fronts and sinks and also VSM-maps together with time studies based on the Continuous method. Analyzes of 5S and ergonomics was completed to find flaws which the company could fix if they decide to implement the finished layout proposal. The documented data of the current situation was used during the development of the finished layout proposal. The layout planning method was used when developing the layout proposals. In the project five layout proposals were developed, where relevant staff got to review and give feedback, which resulted in a final layout proposal. The final layout that was developed created extra space in the grinding room and outside in the production for a total of 38m2. This is extra space that the company can use to develop other parts of the production. In the final layout proposal, unnecessary moments have been decreased because the space for RFI-loading area moved closer to station 1 and 3, which are working on products from the RFI-flow. The computer that the grinding workers stamps in on, for each order, was moved closer to each station to be able to decrease the unnecessary moments in the grinding room. If more of the same product type are supposed to be grinded, the grinding workers stamps in all of the products at the same time. Because the distance between the stations and the computer and the load areas in the final layout has decreased, the hopes are that the grinding workers stop stamping in multiple products at the same time, which will lead to more correct data for the company about how long the grinding work takes.

Nimoverken is the world's largest producer of drying cabinets, located in Hova, Sweden. Drying cabinets are sold mainly in the Nordic countries and to a lesser degree to USA, England and South Korea, where drying cabinets are an increasing niche product on the market. Nimoverken has over 70 years of experience in the manufacture of sheet metal products. Nimoverken wishes to investigate the current situation and develop a more efficient work method. Demand for large drying cabinets has increased steadily in recent years and it is forecasted to continue to increase in the future. Nimoverken therefore has a desire to investigate whether it is possible to increase production capacity. To explore possibilities, an exploratory case study is conducted to investigate whether there are better, more efficient alternatives to their production system. During the preliminary analysis, which is based on observations and discussions with management and the operators, it emerged that standards were deficient at the assembly department for large drying cabinets. These standards are the basis for all forms of continuous improvement according to LEAN philosophy. The purpose of the report is therefore to produce proposals as a basis for a new standardized working method for the assembly department of large drying cabinets. The case study is limited to manual operations for the assembly department of large drying cabinets. The study lasts for a limited time, hence the delimitations in which product family is studied. Delimitation is formed according to production quantity analysis (PQ-analysis). The proportion of operations the product family undergoes is studied through product quantity process routing analysis (PQPR analysis), where products that are of higher quantity and routed through a larger proportion of operations are prioritized. Based on the basis of standardized work, proposals for a new layout based on method standard, production flow, material flow, and information flow have been investigated. The efficiency of a new layout with current and proposed standards are compared with the results of the current production strategy. The current production system meets only 78.2% of demand, which requires the deployment of extra staff than planned. Standards in production flow and material flow according to proposals minimize waste. Standards in information flow minimize necessary waste in the form of work-related conversations. Together, this represents a potential improved lead time of up to 27%. With this, the case study shows that implementing a documented standardized work method can provide direct benefits and form the basis for continuous improvements. By standardizing the work and balancing stations, the case study shows that with currently planned staffing an opportunity is given to meet today's demand and the ability to meet an increased customer demand of up to 40.8%. Suggestions given in the case study are the basis for future implementations. There are lots of possibilities that can shape a layout. The proposals studied in the case study are based on a holistic LEAN-perspective with the aim achieve one-piece flow. / Nimoverken är världens största producent av torkskåp, lokaliserad i Hova, Sverige. Torkskåp säljs främst i Norden samt i USA, England och Sydkorea där torkskåp är en ökande nischprodukt på marknaden. Nimoverken har över 70 års erfarenhet av tillverkning av plåtprodukter. Nimoverken önskar att undersöka nuläget och ta fram ett mer effektivt arbetssätt. Efterfrågan för stora torkskåp har ökat konstant över de senaste åren och det prognostiseras fortsätta öka i framtiden. Nimoverken har därav en önskan att undersöka om det är möjligt att öka produktionskapaciteten. För att utforska möjligheter genomförs en explorativ fallstudie för att utreda om det finns bättre, mer effektiva alternativ till deras produktionssystem. Under den preliminära analysen som är baserad på observationer och diskussioner med ledningar och operatörerna, konstaterades det att på monteringsavdelningen för stora torkskåp, saknas eller följs inte satta standarder. Dessa standarder är grunden till all form av kontinuerliga förbättringar enligt LEAN filosofin. Projektets syfte är därav att ta fram förslag som underlag för nytt standardiserat arbetssätt för monteringsavdelning av stora torkskåp. Fallstudien avgränsas till manuella operationer för monteringsavdelningen av stora torkskåp. Studien pågår under en begränsad tid, därav krävs avgränsningar i vilken produktfamilj som studeras. Avgränsning formas utefter tillverkningskvantitet genom produktkvantitetsanalys (PQ-analys) och andel operationer produktfamiljen genomgår via en produktkvantitetsprocess dirigeringsanalys (PQPR-analys), där högre kvantitet och större andel operationer prioriteras. Utifrån grunden med standardiserat arbete har förslag av ny layout baserat på metodstandard, produktionsflöde, materialflöde, och informationsflöde undersökts. Effektiviteten av en ny layout med integrerade standarder jämförs med resultat av nuvarande produktionsstrategi. Nuvarande produktionssystem bemöter enbart 78,2 % av efterfrågan vilket kräver insättning av extra personal än vad som är planerat. Standarder i produktionsflöde och materialflödet enligt förslag minimerar NNVA (”Necessary but Non Value Adding”) av transporter. Standarder i informationsflöde minimerar NNVA i form av arbetsrelaterade samtal. Tillsammans utgör detta en potentiell förbättrad ledtid upp till 27 %. Med detta visar fallstudien att implementera ett standardiserat arbete kan ge direkta förtjänster och utgöra grunden för kontinuerliga förbättringar. Genom att standardisera arbetet och balansera stationer påvisar fallstudien att med planerad bemanning (ej extra personal) ges en möjlighet att bemöta dagens efterfråga samt en ökad kundefterfråga upp till 40,8 %. Förslag givna i fallstudien är underlag för framtida implementeringar. Det finns mängder av möjligheter som kan forma en layout där de förslag som studeras i fallstudien är baserade på ett holistiskt LEAN-perspektiv och den forskning som finns tillgänglig inom berört område. Förslag har skapats för att knyta ihop alla standarder med en produktionslayout baserat på enstycksflöde.

An increasing expectation from customers creates a need for companies to sharpen their competition factors constantly. There are great competition challenges regarding production costs in Sweden compared to offshoring. Sweden’s answer for competition about production costs has been productional innovation, where the development is bringing the industries closer to a fourth industrial revolution – industry 4.0. This writing discusses a case study performed on Thule Sweden AB to analyze a strategic investment in form of an automatization of palletizing and pallet-handling. This through analyzing what changes, savings and risks the automatization causes. The purpose of the study is not only to carry out an investment analysis, but also to create a general process for investment analyses of strategic decisions. A strategic investment requires a cross organizational analysis due to the extensive consequences. Analyzing a strategic investment requires more aspects then the economic, wherefore a more complex investment requires greater efforts in terms of involvement of different skills. A clear strategy and a good overview of the chosen production section should bring forth alternatives of investments. The investment process that is presented in the study creates a framework for an investment. This study uses, among other fundamental methods in production technology, the PENG-model, where the direct and the indirect benefits that the investments entail are analyzed. The investment is estimated to reduce the annual cost of the observed production segment at Thule Sweden AB by a total of 16,6%. The changes caused by the investment is further analyzed with a risk assessment. The conclusion of the analysis is that Thule Sweden AB should proceed the investment process, since an automatization of palletizing and pallet-handling brings savings, work environmental advantages, and is aligned to both Thule’s strategy and industry 4.0. / En alltmer ökande förväntning från kunder gör att företag ständigt behöver vässa sina konkurrensfaktorer för att vara fortsatt ekonomiskt hållbara. I Sverige finns det utmaningar i att konkurrera om produktionskostnader jämfört med offshoring. Svaret på konkurrens om produktionskostnader har för Sverige varit produktionsinnovation, där utvecklingen för att hantera konkurrensen gör att företagen går mot en fjärde industriell revolution - industri 4.0. Detta arbete behandlar en fallstudie utfört på Thule Sweden AB för att analysera en strategisk investering i form av automatisering gällande palletering och pallhantering. Detta genom att analysera vilka förändringar, besparingar, samt risker en sådan investering ger upphov till. Syftet med studien är, förutom att genomföra en investeringsanalys, att skapa en generell process för investeringsanalyser vid strategiska beslut. En strategisk investering kräver en tvärorganisatorisk analys då konsekvenserna ofta är omfattande. Att analysera en strategisk investering kräver också fler aspekter än den ekonomiska, varför en mer komplex investering kräver ett större arbete gällande involvering av olika kompetenser. En tydlig strategi och god överblicksbild av det valda produktionsavsnittet ska mynna ut i olika alternativ för investering. Investeringsprocessen som presenteras i studien skapar ett ramverk för en investering. Förutom grundläggande produktionstekniska metoder för att identifiera kostnadsbesparingspotentialen med den nya investeringen använder studien också PENG-modellen där de direkta och indirekta nyttorna som investeringen medför analyseras. Investeringen beräknas reducera årskostnaden för det aktuella produktionssegmentet hos Thule Sweden AB med totalt 16,6%. Förändringarna som investeringen ger upphov till analyseras vidare genom en riskanalys. Genom denna analys rekommenderas Thule Sweden AB att fortsätta arbetet med investeringen. Detta för att en automatisering av palletering och pallhantering medför stora besparingar, arbetsmiljömässiga fördelar, samt att det ligger i linje med både Thule Sweden AB’s strategi och industri 4.0.

Industrial housing is the strategy of the future for efficient housing. The strategy exploits the principles and work methods of production systems and is applied to the construction industry. Traditionally the construction sector considers production of one-of-a-kind products as de facto solutions. However, this strategy requires new paradigms, supporting methodologies and business models. The purpose of this thesis is to present and describe a business model that supports the strategy, which meet the project oriented market’s one-of-a-kind demands with customized multi-story houses. Industrial manufacturing of customized houses can be accomplished by industrial strategies, such as Mass Customization. The prerequisites are that the organizational properties, mentioned in the list below, have to be integrated and adjusted to the elementary principles of industrial production and Mass Customization. Fundamental philosophy of the Company Organizational Structure and Management Market and Business Process Product ModelProduction System Information and Communication Systems In this thesis an industrial approach was used to identify the fundamental characteristics in industrial manufacturing and Mass Customization, and its influence of the organizational properties for industrial housing. The foundations of industrial production are a standardized product structure, standardized processes, manual and machine operations, process oriented production, and controlled material flow. Mass Customization is a strategy to achieve customized but industrial produced products with the same efficiency as mass production. It is based on standardized product models, which can be configured and flexible production systems, in which process and resources can be reconfigured in a systematic way. On the basis of this a normative business model (The MC-House) was developed, empirical tested and validated through case studies. The truck manufacture, Scania CV AB, and the industrial housing entrepreneur, NCC Komponent AB, were investigated by interviews and company archives. The result showed that on organizational property level the business model was generic and valid for industrial manufacturing of discrete configured products. In what extent individual products could be configured and produced with a certain performance, require different designs within the organizational properties. The more individual configuration that could be managed, the more complex the executive management gets. To achieve an effective business the complexity has to be met by definition, systemizing, and integration on the corresponding organizational hierarchic level as the configuration is managed. When considered the fundamental characteristics of construction, buildings has to be assembled there it will be used, the result also showed that the production system for industrial housing should be divided in two. One stationary manufacturing system, the factory, and one mobile assemble system at the construction site. Another condition that has to be considered is that the generic product model should be able to meet the local requirements. Further the study indicated that the a industrial housing company is different from a traditional construction company, regarding the organizational structure, the market management, production approach, product model handling, business and project processes. Within an industrial housing company the activity is process oriented around the continuous production process. This mean that a house or a project cannot be considered as strictly unique, rather just another order which is made of standardized components, produced in the same process and with same recourses as previous and future other orders. In fact an industrial housing company has more in common with organizations of industrial manufacturing than with classical construction entrepreneurs organized for project oriented and hand craft production. / QC 20101111

In today’s fast-paced industrial landscape, the drive for greater efficiency and flexibility in product development has sparked significant interest in innovative automation technologies. This thesis explores the usefulness of various automation techniques for customized products such as Knowledge-Based Engineering (KBE), Multidisciplinary Optimization (MDO) and machine learning frameworks. The research begins by establishing an automated framework for fixture design, combining design automation and MDO to streamline the design process. It then moves to optimizing gas turbines, introducing an automation framework that merges CAD templates with KBE principles. For complex and unstructured production, this thesis explores the use of Reinforcement Learning (RL) to tackle challenges in unstructured manufacturing. By utilizing lightweight physics-based engines and RL, the research advances automated assembly validation and mobile robot operations, pushing the boundaries of adaptive production automation. Furthermore, a framework is developed, which integrates smoothly with industrial robotic platforms showcases practical automation solutions and highlights the adaptability and applicability of digital twin technology in real-world situations. This thesis contributes to the field of product development by providing innovative solutions that are rooted in multidisciplinary research. It bridges the theoretical and practical aspects of automation with solutions that overcomes the obstacles to realize seamless integration between digital and physical realities in a manufacturing context.

En fallstudie har utförts på en tillverkningsorganisation där kontrollprocessen precis genomgått en strukturell förändring och är därför i behov av förbättring. Studiens syfte var att studera variationer i de standardiserade arbetssätten och analysera resultaten för att framställa de underliggande orsakerna till variationen. Studien baseras på teorier om Offensiv kvalitetsutveckling och Lean Management. För att framställa ett resultat har en kvalitativ forskningsmetod använts för att utvärdera de skillnader som återfinns mellan de standardiserade arbetssätten och det faktiska genomförandet. Datamängder har samlats in genom en variation av källor. Dokumentstudier, litteraturstudier, ostrukturerade intervjuer och observationer har använts för att sammanställa ett resultat. Resultatet påvisar flera skillnader i de arbetsrutiner som ska finnas som stöd till operatörerna. Resultaten styrks av observationer som påvisar flera skillnader mellan operatörernas faktiska arbetssätt. Litteraturstudien framställer i en uppsättning egenskaper och tillvägagångssätt som framhäver en framgångsrik implementering utav Lean i en process. Analys av datainsamling sammanfattar att organisatoriska brister återfinns i tillverkningsorganisationen. Brister i konsekvent upplärning har lett till variationer i arbetssätt mellan operatörer. Brister i ledningens roll för processtyrning kan ha föranlett avvikelserna i genomförandet bland operatörer och i arbetsrutinerna. För att tillverkningsorganisationen ska kunna förbättras har slutsatserna grundat en uppsättning implementeringsförslag som går att integrera i den studerade organisationens interna format för ständiga förbättringar. / A case study was conducted within a manufacturing organization that recently underwent a structural change in its control process, necessitating improvements. The study aims to examine variations in standardized work methods and analyze the results to identify underlying causes of these variations. Grounded in theories of Total Quality Management and Lean management, the research employs a qualitative methodology to evaluate the discrepancies between standardized procedures and actual implementation. Data were collected from various sources, including document reviews, literature reviews, unstructured interviews, and observations, to compile the findings. The results reveal significant differences in the work routines intended to support operators, corroborated by observations of discrepancies in operators' actual practices. The literature review highlights characteristics and approaches essential for the successful implementation of Lean in processes. The data analysis concludes that organizational deficiencies exist within the manufacturing organization. Inconsistent training has led to variations in operators' practices, and shortcomings in management's role in process control may have contributed to deviations in implementation and work descriptions. To enhance the manufacturing organization, the conclusions provide a set of implementation proposals for integration into the organization's internal continuous improvement framework.

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There are many people in the world who use bikes in todays society. The problem with derailing of the drivechain has no standardized solution as of yet. This thesis is based on a prototype which would solve the problem for the cyclist without the need for stoping to remount the drivechain.The purpose of the thesis is to make new designs of the unique parts of the product and adapt them for suitable materials and manufacturing methods. Two manufacturing methods were also chosen in the thesis to calculate which of the methods were the most profitable at different sizes of the series. The last part was to remake the models of all parts so that they could be both easily applied and manufactured in a simple and profitable way. A simplified method of DFM (Design for Manufacturing) was used for the development of the product in writing this thesis along with consultations of professionals in their field.The result was not only a mechanism with better functionality but also a product adapted to two different manufacturing methods, machining and injection molding. The cost of the series studied in this thesis was large and big series are required for profitable manufacturing.