This report analyzes disposable packaging and returnable packaging with the methods life cycle analysis and life cycle costs analysis. These two different packaging are analyzed through the company Clas Ohlson’s packaging-flow. To get a picture of how the flow works, a visit at the company and email contact have been done with Clas Ohlson to get relevant information Today Clas Ohlson has a big flow of articles to the stores without larger variations in the demand, with the exception of autumn, which is when customers start shopping for Christmas. Clas Ohlson’s articles are placed on a pallet and are wrapped into plastic-film for protection and to make sure that nothing will be stolen. In this report Plastic-film is compared to the company Nycopac AB’s product Nyco Sleeve. In Sweden Posten takes care of Clas Ohlson’s transports and is the company’s third party-logistics provider. Nyco Sleeve is a type of pallet box, which is placed on a pallet with the possibility to place three units upon each other. The pallet box is possible to fold, which makes it doable to place pallet boxes upon each other in reverse transportation. Our Life cycle costs analysis shows that Nyco Sleeve is profitable compared to continue using plastic-film as secondary packaging. Nyco Sleeve demands a larger investment, almost seven times larger than the price for plastic-film but the expenses will be recovered relatively fast because of decreasing transportation costs. Posten’s pricing depends on each pallet place that is used which means that Nyco Sleeve’s higher weight does not affect the price. The total costs decreases because Nyco Sleeve increases the fill ratio on each pallet place, which results that less pallet places need to be used in the transport. If Nyco Sleeve is used the total pallet places decrease from about 116 000 to about 93 000 pallets considering 2012s flow. Due to decreasing costs each year, the pay-off-method shows that the investment reaches break even in about 0.7 years The life cycle analysis that examines the environmental impact of the packaging shows the same trend as the life cycle cost analysis, it is the transport that has the decisive influence on the environment. Important to note is that the transportations from Clas Ohlson’s warehouse to stores and the reverse transports stand for the largest carbon dioxide emissions and not the transportations from production or to waste disposal. The production phase’s emission is also important especially for Nyco Sleeve, which causes large amounts of emission compared to the plastic film. Decreasing transportations and that it is possible to reuse Nyco Sleeve even out the differences between the two packaging types when it comes to emission in production. The life cycle analysis’ scenario analysis shows that Nyco Sleeve environmental impact reaches break even after about two years compared to break even for the economic costs in 0.7 years. If only one loop is investigated the calculations show that Nyco Sleeve has larger environmental impact then plastic film but over time and when several loops are considered Nyco Sleeves carbon dioxide emission is economized. / Rapporten analyserar engångs- och returemballage genom de två analysmetoderna, livscykelkostnads- och livscykelanalys. Emballagen analyseras utifrån företaget Clas Ohlsons emballageflöde där studiebesök gjorts för att se hur flödet fungerar. Mailkontakt har också förekommit för annan viktig information kring företagets flöde av artiklar och emballage. Clas Ohlson har idag ett stort och jämnt flöde av produkter till deras butiker med säsongstoppar på hösten inför julhandeln. Deras produkter paketeras idag på lastpallar som sedan sveps in i plastfilm för att skydda och säkerställa att ingen stöld har skett. Det är detta engångsemballage, plastfilm, som jämförs emot returemballaget, Nyco Sleeve. Clas Ohlsons transporter sker idag med en tredjepartslogistiker där Posten är deras distributör inom Sveriges gränser, som är det system som undersöks. Nyco Sleeve är en form av pallbox som ställs på en lastpall och det går lasta tre stycken i höjd, ovan på varandra. Pallboxen går att fälla ihop vid returer och lastas även då ovan på varandra. Livscykelkostnadsanalysen visar att Nyco Sleeve är en ekonomisk lönsam investering i relation till att behålla plastfilmen som sekundärförpackning. Kostnaden att investera i Nyco Sleeve är ca sju gånger högre i jämförelse med inköpskostnaden för plastfilmen, men investeringen blir lönsam relativt snabbt eftersom Nyco Sleeve sänker transportkostnaderna. Posten tar idag betalt per pallplats och därmed gör inte tyngden på en Nyco Sleeve någon påverkan på den ekonomiska kostnaden. Kostnaden minskar genom användning av Nyco Sleeve eftersom fyllnadsgraden ökar och därmed minskar antalet levererade pallplatser. Skulle Nyco Sleeve användas minskas antalet från 116 100 stycken till ca 93 000 pallplatser utifrån Clas Ohlsons flöde under 2012. Genom den stora transportbesparingen per år visar pay-off-metoden att investeringen når break-even efter omkring 0,7 år. Livscykelanalysen som undersöker emballagens koldioxidutsläpp visar på samma tendens som livscykelkostnadsanalysen, att det är transporten som är den stora miljöboven. Viktigt att poängtera är att det är transporterna från Clas Ohlsons centrallager ut till butikerna och returtransporterna för samma sträcka som ger störst miljöpåverkan och inte transporterna från emballagens produktionsanläggningar till centrallagret eller till avfallshanteringen. Produktionen är även den en stor aktivitet som ger stor miljöpåverkan där Nyco Sleeve bidrar till betydligt större utsläpp än plastfilmen. Den stora skillnaden i miljöpåverkan från produktionen kompenseras genom de minskade transporterna och att Nyco Sleeve återanvänds. Livscykelanalysens scenarioanalys visar att Nyco Sleeves miljöpåverkan når break even efter ca två år. Undersöks bara en loop visar beräkningarna att Nyco Sleeve har större miljöpåverkan än om plastfilm används men detta inbesparas genom de minskade transporterna.

Virgin aggregate is being used faster than it is being made available creating a foreseeable shortage in the future. Despite this trend, the availability of demolished concrete for use as recycled concrete aggregate (RCA) is increasing. Using this waste concrete as RCA conserves virgin aggregate, reduces the impact on landfills, decreases energy consumption and can provide cost savings. However, there are still many unanswered questions on the beneficial use of RCA in concrete pavements. This research addresses the many technical and cost-effective concerns regarding the use of RCA in concrete pavements by identifying concrete mixture and proportioning designs suitable for jointed plain concrete pavements; constructing test sections using varying amounts of RCA; monitoring performance through testing, condition surveys and sensor data; modeling RCA pavement performance; and predicting life cycle costs. The research was carried out as a partnership between the Centre for Pavement and Transportation Technology (CPATT) at the University of Waterloo, the Cement Association of Canada, Dufferin Construction, and the Natural Sciences and Engineering Research Council of Canada. The literature review provides an overview of sustainability and key performance indicators, the material properties of RCA both as an aggregate and in concrete, concrete mixture and proportioning designs with RCA, performance of existing RCA pavements, and the implementation of RCA highlighting some examples where RCA has been used successfully. Twelve preliminary mixes were developed using three total cementitious contents amounts of 315 kg/m3, 330 kg/m3, and 345 kg/m3 to determine four suitable mixes with varying coarse RCA contents (0%, 15%, 30% and 50%) to place at the CPATT test track. At 28-days, all of the twelve mixes exceed the 30 MPa design strength. Four test sections containing 0%, 15%, 30% and 50% coarse RCA were constructed in June 2007. The test sections had identical cross sections consisting of 250 mm portland cement concrete (PCC), 100 mm asphalt-stabilized OGDL and a 450 mm granular base. For each coarse RCA content, one slab was instrumented with six vibrating wire concrete embedment strain gages to measure long-term longitudinal and transverse strain due to environmental changes, two vibrating wire vertical extensometers to monitor slab curling and warping, two vibrating wire inter-panel extensometers to monitor joint movement, and two maturity meters to measure maturity and temperature. Quality assurance and quality control (QA/QC) testing showed that the mixes containing RCA exhibited similar or improved performance when compared to the conventional concrete for compressive and flexural strength, freeze-thaw durability and coefficient of thermal expansion. Pavement performance of the four test sections was evaluated using visual surveys following the Ontario Ministry of Transportation’s Manual for Condition rating of Rigid Pavements. Nine pavement evaluations have been performed every two to four months since construction. All test sections are in excellent condition with pavement condition index (PCI) values greater than 85 after two years in-service and approximately three hundred thousand Equivalent Single Axle Loads. Sensor data from the strain gauges, and vertical and inter-panel extensometers are providing consistent results between the test sections. Long-term performance modeling using the Mechanistic-Empirical Pavement Design Guide (ME-PDG) showed improved performance with respect to cracked slabs, joint faulting, and pavement roughness as the RCA content increased. Multivariable sensitivity analysis showed that the performance results were sensitive to CTE, unit weight, joint spacing, edge support, surface absorption, and dowel bar diameter. Life cycle cost analysis (LCCA) illustrated the savings that can be expected using RCA as a replacement aggregate source as the cost of virgin aggregate increase as the sources becomes depleted. Multivariable sensitivity analysis showed that the LCCA results were sensitive to construction costs, discount rate, and maintenance and rehabilitation quantities.

Today Scania give a high priority to the continuous improvements on the quality of their vehicles. To follow up the flaws in product quality, which are recognized by the repairs at the local workshops, material requests are carried through to be able to analyze the defects at the plant in Södertälje – in purpose to improve the product quality. The material requests are also carried through to compensate the workshop for their expenses and to check that they are working according to the company’s warranty manual. Due to local routines and different distribution structures at the different markets the lead times and the costs caused by the flow of material are hard to estimate. Furthermore the lead times are in many cases unjustified long, which imply that the information about quality problems reaches Scania at a late stage. The variations in lead times moreover results in problems with planning the activities. This study has, in the light of the background described above, aimed to map and analyze the lead times and costs which are caused by the flow of warranty material, from the company’s workshops to the plant in Södertälje. Based on the results of the analysis a range of alternative solutions also have been prepared in purpose to reduce the lead times in a cost efficient way. The mapping, which took place on the Swedish, German and Benelux markets, has mainly been carried out through visits at the workshops and the distributors at respective markets. Apart from the qualitative aspects in collected data the performance of the studied markets, in the form of costs and lead times, has been compiled and calculated. The observed characteristics were later on analyzed together with relevant logistics management theory to point out strengths and weaknesses with different solutions. Based on the mapping and the analysis the second part of the study could be completed, which aimed to formulate a range of recommendations. The recommendations, which are presented below, are principally formulated in correspondence with the priorities of Scania – namely to achieve high product quality and rapid information. <ol type="1">Improved and more concrete management at factory level. This can be achieved through clarified targets which include explicit measurements and directives towards all actors. Reduce the waiting time between activities. This can be achieved by a combination of incentives and demands on the distributors as well as on the workshops. Change the transport strategies. On the Benelux market the transport solutions are well designed and are therefore both cost effective and quite fast, which implies short lead times. On the Swedish market a consolidation of goods is proposed to decrease the delivery rate in Södertälje to just once a week. On the German market merged deliveries are proposed, the same transport that delivers spare parts to the workshop will through this recommendation also pick up the warranty material. The warranty material will in this solution also be merged in a collection point and thereafter be transported to the distributor once a week. Change the transport frequencies. The different markets will send in material on predefined days once a week, which will contribute to keep the lead times short and the quantities at a more manageable level. Even out the inflow of material to Södertälje and avoid handling in Building 220X, to reduce the problems with stress, mishandling and lack of recourses which occur because of the uneven inflow at the receiving area today. Clear information should in according to this be given to each market concerning for instance shipping date and quantities. Improve the integration of the information systems, to facilitate the spreading of information and administrative activities related to claims and material requests. This also implies that forecasting and management is facilitated.   Through the recommendations the lead time for the Swedish market is estimated to be reduced from 21 to 13 days, for the German market from 60 to 21 days and from 39 to 21 days for the Benelux-market. Apart from reduced lead times the more straight demands, incentives and improved routines will imply that the variations in lead times are reduced. Due to the changes according to the recommendations the costs will be reduced, both through the reduced lead times, which affect the capital costs, as well as more efficient structures that reduce the handling costs and the costs of transportation. / Scania lägger idag ner stor energi på att ständigt utveckla kvaliteten på de tillverkade fordonen. I avsikt att följa upp de kvalitetsbrister som uppdagas vid reparationer ute på företagets service­verkstäder genomförs materialhemtagningar för att centralt kunna analysera defekterna och utveckla kvaliteten, men också för att ersätta verkstädernas utlägg och kontrollera att de följer garantimanualens föreskrifter. Beroende på lokala rutiner och varierande upplägg av respektive marknads distributionsstruktur är de ledtider och kostnader som dessa materialflöden idag medför svåra att uppskatta. Ledtiderna är dessutom i många fall omotiverat långa vilket medför att informationen om kvalitetsbrister ankommer Scania sent. Dessutom medför variationerna i ledtiden att det blir svårt att planera verksamheten. Denna studie har utifrån ovanstående bakgrund avsett att kartlägga och analysera de ledtider och kostnader som uppstår i materialflödet av returmaterial, från Scanias serviceverkstäder via distributören till fabriken i Södertälje. Utifrån analysresultaten har alternativa lösningar utarbetats för att på ett kostnadseffektivt sätt reducera ledtiderna. Kartläggningen som skedde på marknaderna i Sverige, Tyskland och Benelux har huvudsakligen genomförts via besök hos distributörer och serviceverkstäder på respektive marknad och har sammanställts i ett empiriunderlag. Förutom de mer kvalitativa aspekterna i detta underlag har respektive marknads prestanda, i form av kostnader och ledtider, sammanställts och beräknats. De observerade egenskaperna på de studerade marknaderna kunde tillsammans med relevant teori analyseras för att påvisa styrkor och svagheter med olika upplägg och lösningar. Utifrån kartläggning och analys kunde studiens andra del fullbordas, vilken avsåg att ta fram rekommendationer för åtgärder som medförde ett kostnadseffektivare upplägg och samtidigt reducerade ledtider. Rekommendationerna som nedan presenteras har utgått från de prioriteringar som gjordes i analysen, vilka huvudsakligen utgår från Scanias strävan efter hög produktkvalitet och snabb information, vilket indirekt implicerar korta ledtider. <ol type="1">Förbättrad styrning/mätning från fabrik, genom formulering av tydliga målsättningar från fabrik centralt, vilket omfattar definiering av explicita mätpunkter och kommunikation av tydliga krav och incitament gentemot övriga aktörer. Minska väntetiden mellan aktiviteterna, genom att införa krav och/eller incitament, enligt resonemanget ovan, gentemot serviceverkstäder och distributörer. Detta ökar prioriteten samtidigt som utformandet av bättre rutiner stimuleras. Förändra flödesvägar och transportstrategier. För Benelux-marknaden bedöms de befintliga transportstrategierna fungera bra då de är både kostnadseffektiva och samtidigt medför korta ledtider. På den svenska marknaden kan efter analys konstateras att dagens lösning är ett fullgott alternativ, men för att undvika de ojämna inleveranserna rekommenderas att en konsolidering av godset genomförs för vidare inleverans en gång per vecka. För den tyska marknaden föreslås samleveranser, så kallade mjölkrundor, i samband med reservdelsleveranserna som levererar godset till ett antal uppsamlingsplatser. Från uppsamlingsplatserna bör godset skickas till distributören som efter besiktning levererar godset vidare till Södertälje. Förändra transportfrekvenserna, in till fabrik till en gång per vecka för samtliga marknader för att samla ihop hanterbara mängder från marknaden och samtidigt hålla ledtiden nere. Jämna ut inflödet till Södertälje och undvik hantering i byggnad 220X, för att minska problemen med stress, felhantering och resursbrist som uppstår i och med dagens ojämna flöde vid ankomstmottagningen i byggnad 280. Tydliga besked bör här ges till respektive marknad om exempelvis vilka avskeppningsdatum och vilken information som efterfrågas. Förbättra systemstödet, för att underlätta informationsspridning och administrativa aktiviteter relaterade till reklamationer och materialhemtagningar, vilket också innebär att endast önskat material tas hem och prognostisering och styrning underlättas.   Genom de föreslagna åtgärderna har ledtiderna för Sverige beräknats minska från 21 till 13 dagar, för Tyskland från 60 till 21 dagar och för Benelux från 39 till 21 dagar. Förutom kortare ledtider innebär tydligare krav och incitament tillsammans med förbättrade rutiner att variationerna i ledtiderna minskar. Baserat på de utarbetade rekommendationerna minskar också kostnaderna både genom minskade ledtider, vilket påverkar lagerföringskostnaderna, och genom effektivare upplägg som minskar lagerhållningskostnaderna och transportkostnaderna.

Virgin aggregate is being used faster than it is being made available creating a foreseeable shortage in the future. Despite this trend, the availability of demolished concrete for use as recycled concrete aggregate (RCA) is increasing. Using this waste concrete as RCA conserves virgin aggregate, reduces the impact on landfills, decreases energy consumption and can provide cost savings. However, there are still many unanswered questions on the beneficial use of RCA in concrete pavements. This research addresses the many technical and cost-effective concerns regarding the use of RCA in concrete pavements by identifying concrete mixture and proportioning designs suitable for jointed plain concrete pavements; constructing test sections using varying amounts of RCA; monitoring performance through testing, condition surveys and sensor data; modeling RCA pavement performance; and predicting life cycle costs. The research was carried out as a partnership between the Centre for Pavement and Transportation Technology (CPATT) at the University of Waterloo, the Cement Association of Canada, Dufferin Construction, and the Natural Sciences and Engineering Research Council of Canada. The literature review provides an overview of sustainability and key performance indicators, the material properties of RCA both as an aggregate and in concrete, concrete mixture and proportioning designs with RCA, performance of existing RCA pavements, and the implementation of RCA highlighting some examples where RCA has been used successfully. Twelve preliminary mixes were developed using three total cementitious contents amounts of 315 kg/m3, 330 kg/m3, and 345 kg/m3 to determine four suitable mixes with varying coarse RCA contents (0%, 15%, 30% and 50%) to place at the CPATT test track. At 28-days, all of the twelve mixes exceed the 30 MPa design strength. Four test sections containing 0%, 15%, 30% and 50% coarse RCA were constructed in June 2007. The test sections had identical cross sections consisting of 250 mm portland cement concrete (PCC), 100 mm asphalt-stabilized OGDL and a 450 mm granular base. For each coarse RCA content, one slab was instrumented with six vibrating wire concrete embedment strain gages to measure long-term longitudinal and transverse strain due to environmental changes, two vibrating wire vertical extensometers to monitor slab curling and warping, two vibrating wire inter-panel extensometers to monitor joint movement, and two maturity meters to measure maturity and temperature. Quality assurance and quality control (QA/QC) testing showed that the mixes containing RCA exhibited similar or improved performance when compared to the conventional concrete for compressive and flexural strength, freeze-thaw durability and coefficient of thermal expansion. Pavement performance of the four test sections was evaluated using visual surveys following the Ontario Ministry of Transportation’s Manual for Condition rating of Rigid Pavements. Nine pavement evaluations have been performed every two to four months since construction. All test sections are in excellent condition with pavement condition index (PCI) values greater than 85 after two years in-service and approximately three hundred thousand Equivalent Single Axle Loads. Sensor data from the strain gauges, and vertical and inter-panel extensometers are providing consistent results between the test sections. Long-term performance modeling using the Mechanistic-Empirical Pavement Design Guide (ME-PDG) showed improved performance with respect to cracked slabs, joint faulting, and pavement roughness as the RCA content increased. Multivariable sensitivity analysis showed that the performance results were sensitive to CTE, unit weight, joint spacing, edge support, surface absorption, and dowel bar diameter. Life cycle cost analysis (LCCA) illustrated the savings that can be expected using RCA as a replacement aggregate source as the cost of virgin aggregate increase as the sources becomes depleted. Multivariable sensitivity analysis showed that the LCCA results were sensitive to construction costs, discount rate, and maintenance and rehabilitation quantities.

The purpose of this thesis is to develop a model for assessing cost effectiveness of applying lean tools. The model consists of eight phases: it starts by understanding customers' requirements using Voice of Customer (VOC) and Quality Function Deployment (QFD) tools. In phase 2, the current state of plant is assessed using lean profile charts based on Balanced Scorecard (BSC) measures. In phase 3 and phase 4, identification of critical problem(s) and generating of improvement suggestion(s) are performed. Phase 5 provide evaluation of the cost effectiveness of implementing the suggested lean methods based on life cycle cost analysis (LCCA) and phase 6 prefers the right alternative based on multiple criteria decision making (MCDM). In phase 7 the selected alternative is supposed to be implemented and finally the user should monitor and control the process to make sure that the improvement is going as planned. The model was verified successfully using a case study methodology at one Swedish sawmill called Södra Timber in Ramkvilla, one part of Södra group. Results obtained from the study showed that the production and human resources perspectives are the most critical problem areas that need to be improved. They got the lowest scores in the lean profile, 63% and 68%, respectively. Using value stream mapping (VSM) it was found that the non value added (NVA) ratios for the core and side products are 87.4% and 90.4%, respectively. Using the model, three improvement alternatives were suggested and evaluated using LCCA and MCDM. Consequently, implementing 5S got the highest score, second came redesigning the facility layout. However, it was estimated that 4.7 % of NVA for the side product would be reduced by redesigning the facility layout. The recommendations were suggested for the company to improve their performance. The novelty of the thesis is based on the fact that it addresses two main issues related to lean manufacturing: firstly, suggesting lean techniques based on assessment of lean profile that is based on BSC and QFD, and secondly assessing the cost effectiveness of the suggested lean methods based on LCCA and MCDM. This thesis provides a generalized model that enables the decision-maker to know and measure, holistically, the company performance with respect to customer requirements. This will enable the company to analyze the critical problems, suggest solutions, evaluate them and make a cost effective decision. Thus, the company can improve its competitiveness.

In this study a recent dam type, concrete face rockfill dam (CFRD), its design and behaviour is overviewed. The design features of G&ouml / k&ccedil / eler Dam are introduced as a case study. Selection of concrete face rockfill type for G&ouml / k&ccedil / eler Dam Project is discussed together with the other two alternatives, namely earth core rockfill (ECRD) and roller compacted concrete (RCC) dam. G&ouml / k&ccedil / eler Dam type selection as concrete face rockfill dam is also verified by an economic analysis conducted calculating internal rate of return for all alternative types. In cost analysis a currency independent defined unit cost (DUC) is specified to verify the time independent validity of the economic analysis.

Historically, transportation asset management has focused on roadways and bridges, but more recently, many agencies are looking to extend their programs to ancillary assets such as traffic signs and guardrails. This thesis investigates the state of practice of managing these assets in order to assess the data and system needs for successful program implementation, and further reviews the opportunities for making a business case for formal management procedures based on quantified benefits of managing ancillary assets. The asset classes, selected from a review of asset management literature, include culverts, earth retaining structures, guardrails, mitigation features, pavement markings, sidewalks and curbs, street lights, traffic signals, traffic signs and utilities and manholes, with data as an information asset. Findings from a literature review showed that a number of agencies have made substantial efforts to manage their ancillary transportation assets; however, methods and practices vary. Specific state and municipal agencies identified from the literature review were surveyed for further details on their practices. The survey results show significant knowledge gaps in data collection cost estimates, and cost savings from the implementation of a transportation asset management program for ancillary assets. Finally, this work evaluates the opportunities to quantify the benefits of ancillary transportation asset management, indicating several challenges due to a lack of the data needed. The results obtained highlight the current state of practice, revealing opportunities and challenges for improving the management of ancillary transportation assets.

<p>Today Scania give a high priority to the continuous improvements on the quality of their vehicles. To follow up the flaws in product quality, which are recognized by the repairs at the local workshops, material requests are carried through to be able to analyze the defects at the plant in Södertälje – in purpose to improve the product quality. The material requests are also carried through to compensate the workshop for their expenses and to check that they are working according to the company’s warranty manual.</p><p>Due to local routines and different distribution structures at the different markets the lead times and the costs caused by the flow of material are hard to estimate. Furthermore the lead times are in many cases unjustified long, which imply that the information about quality problems reaches Scania at a late stage. The variations in lead times moreover results in problems with planning the activities.</p><p>This study has, in the light of the background described above, aimed to map and analyze the lead times and costs which are caused by the flow of warranty material, from the company’s workshops to the plant in Södertälje. Based on the results of the analysis a range of alternative solutions also have been prepared in purpose to reduce the lead times in a cost efficient way.</p><p>The mapping, which took place on the Swedish, German and Benelux markets, has mainly been carried out through visits at the workshops and the distributors at respective markets. Apart from the qualitative aspects in collected data the performance of the studied markets, in the form of costs and lead times, has been compiled and calculated. The observed characteristics were later on analyzed together with relevant logistics management theory to point out strengths and weaknesses with different solutions.</p><p>Based on the mapping and the analysis the second part of the study could be completed, which aimed to formulate a range of recommendations. The recommendations, which are presented below, are principally formulated in correspondence with the priorities of Scania – namely to achieve high product quality and rapid information.</p><ol type="1"><li><strong>Improved and more concrete management at factory level.</strong> This can be achieved<strong> </strong>through clarified targets which include explicit measurements and directives towards all actors.</li><li><strong>Reduce the waiting time between activities. </strong>This can be achieved by a combination of incentives and demands on the distributors as well as on the workshops. <strong></strong></li><li><strong>Change the transport strategies. </strong>On the Benelux market the transport solutions are well designed and are therefore both cost effective and quite fast, which implies short lead times. On the Swedish market a consolidation of goods is proposed to decrease the delivery rate in Södertälje to just once a week. On the German market merged deliveries are proposed, the same transport that delivers spare parts to the workshop will through this recommendation also pick up the warranty material. The warranty material will in this solution also be merged in a collection point and thereafter be transported to the distributor once a week.<strong></strong></li><li><strong>Change the transport frequencies. </strong>The different markets will send in material on predefined days once a week, which will contribute to keep the lead times short and the quantities at a more manageable level.<strong></strong></li><li><strong>Even out the inflow of material to Södertälje and avoid handling in Building 220X,</strong> to reduce the problems with stress, mishandling and lack of recourses which occur because of the uneven inflow at the receiving area today. Clear information should in according to this be given to each market concerning for instance shipping date and quantities.<strong></strong></li><li><strong>Improve the integration of the information systems,</strong> to facilitate the spreading of information and administrative activities related to claims and material requests. This also implies that forecasting and management is facilitated.<strong></strong></li></ol><p> </p><p>Through the recommendations the lead time for the Swedish market is estimated to be reduced from 21 to 13 days, for the German market from 60 to 21 days and from 39 to 21 days for the Benelux-market. Apart from reduced lead times the more straight demands, incentives and improved routines will imply that the variations in lead times are reduced.</p><p>Due to the changes according to the recommendations the costs will be reduced, both through the reduced lead times, which affect the capital costs, as well as more efficient structures that reduce the handling costs and the costs of transportation.</p> / <p>Scania lägger idag ner stor energi på att ständigt utveckla kvaliteten på de tillverkade fordonen. I avsikt att följa upp de kvalitetsbrister som uppdagas vid reparationer ute på företagets service­verkstäder genomförs materialhemtagningar för att centralt kunna analysera defekterna och utveckla kvaliteten, men också för att ersätta verkstädernas utlägg och kontrollera att de följer garantimanualens föreskrifter.</p><p>Beroende på lokala rutiner och varierande upplägg av respektive marknads distributionsstruktur är de ledtider och kostnader som dessa materialflöden idag medför svåra att uppskatta. Ledtiderna är dessutom i många fall omotiverat långa vilket medför att informationen om kvalitetsbrister ankommer Scania sent. Dessutom medför variationerna i ledtiden att det blir svårt att planera verksamheten.</p><p>Denna studie har utifrån ovanstående bakgrund avsett att kartlägga och analysera de ledtider och kostnader som uppstår i materialflödet av returmaterial, från Scanias serviceverkstäder via distributören till fabriken i Södertälje. Utifrån analysresultaten har alternativa lösningar utarbetats för att på ett kostnadseffektivt sätt reducera ledtiderna.</p><p>Kartläggningen som skedde på marknaderna i Sverige, Tyskland och Benelux har huvudsakligen genomförts via besök hos distributörer och serviceverkstäder på respektive marknad och har sammanställts i ett empiriunderlag. Förutom de mer kvalitativa aspekterna i detta underlag har respektive marknads prestanda, i form av kostnader och ledtider, sammanställts och beräknats. De observerade egenskaperna på de studerade marknaderna kunde tillsammans med relevant teori analyseras för att påvisa styrkor och svagheter med olika upplägg och lösningar.</p><p>Utifrån kartläggning och analys kunde studiens andra del fullbordas, vilken avsåg att ta fram rekommendationer för åtgärder som medförde ett kostnadseffektivare upplägg och samtidigt reducerade ledtider. Rekommendationerna som nedan presenteras har utgått från de prioriteringar som gjordes i analysen, vilka huvudsakligen utgår från Scanias strävan efter hög produktkvalitet och snabb information, vilket indirekt implicerar korta ledtider.</p><ol type="1"><li><strong>Förbättrad styrning/mätning från fabrik</strong>, genom formulering av tydliga målsättningar från fabrik centralt, vilket omfattar definiering av explicita mätpunkter och kommunikation av tydliga krav och incitament gentemot övriga aktörer. </li><li><strong>Minska väntetiden mellan aktiviteterna</strong>, genom att införa krav och/eller incitament, enligt resonemanget ovan, gentemot serviceverkstäder och distributörer. Detta ökar prioriteten samtidigt som utformandet av bättre rutiner stimuleras.</li><li><strong>Förändra flödesvägar och transportstrategier.<em> </em></strong>För Benelux-marknaden bedöms de befintliga transportstrategierna fungera bra då de är både kostnadseffektiva och samtidigt medför korta ledtider. På den svenska marknaden kan efter analys konstateras att dagens lösning är ett fullgott alternativ, men för att undvika de ojämna inleveranserna rekommenderas att en konsolidering av godset genomförs för vidare inleverans en gång per vecka. För den tyska marknaden föreslås samleveranser, så kallade mjölkrundor, i samband med reservdelsleveranserna som levererar godset till ett antal uppsamlingsplatser. Från uppsamlingsplatserna bör godset skickas till distributören som efter besiktning levererar godset vidare till Södertälje.</li><li><strong>Förändra transportfrekvenserna,</strong><em> </em>in till fabrik till en gång per vecka för samtliga marknader för att samla ihop hanterbara mängder från marknaden och samtidigt hålla ledtiden nere. </li><li><strong>Jämna ut inflödet till Södertälje och undvik hantering i byggnad 220X,</strong><em> </em>för att minska problemen med stress, felhantering och resursbrist som uppstår i och med dagens ojämna flöde vid ankomstmottagningen i byggnad 280. Tydliga besked bör här ges till respektive marknad om exempelvis vilka avskeppningsdatum och vilken information som efterfrågas. </li><li><strong>Förbättra systemstödet,</strong> för att underlätta informationsspridning och administrativa aktiviteter relaterade till reklamationer och materialhemtagningar, vilket också innebär att endast önskat material tas hem och prognostisering och styrning underlättas. </li></ol><p> </p><p>Genom de föreslagna åtgärderna har ledtiderna för Sverige beräknats minska från 21 till 13 dagar, för Tyskland från 60 till 21 dagar och för Benelux från 39 till 21 dagar. Förutom kortare ledtider innebär tydligare krav och incitament tillsammans med förbättrade rutiner att variationerna i ledtiderna minskar.</p><p>Baserat på de utarbetade rekommendationerna minskar också kostnaderna både genom minskade ledtider, vilket påverkar lagerföringskostnaderna, och genom effektivare upplägg som minskar lagerhållningskostnaderna och transportkostnaderna.</p>

<p>The purpose of this thesis is to develop a model for assessing cost effectiveness of applying lean tools. The model consists of eight phases: it starts by understanding customers' requirements using Voice of Customer (VOC) and Quality Function Deployment (QFD) tools. In phase 2, the current state of plant is assessed using lean profile charts based on Balanced Scorecard (BSC) measures. In phase 3 and phase 4, identification of critical problem(s) and generating of improvement suggestion(s) are performed. Phase 5 provide evaluation of the cost effectiveness of implementing the suggested lean methods based on life cycle cost analysis (LCCA) and phase 6 prefers the right alternative based on multiple criteria decision making (MCDM). In phase 7 the selected alternative is supposed to be implemented and finally the user should monitor and control the process to make sure that the improvement is going as planned. The model was verified successfully using a case study methodology at one Swedish sawmill called Södra Timber in Ramkvilla, one part of Södra group. Results obtained from the study showed that the production and human resources perspectives are the most critical problem areas that need to be improved. They got the lowest scores in the lean profile, 63% and 68%, respectively. Using value stream mapping (VSM) it was found that the non value added (NVA) ratios for the core and side products are 87.4% and 90.4%, respectively. Using the model, three improvement alternatives were suggested and evaluated using LCCA and MCDM. Consequently, implementing 5S got the highest score, second came redesigning the facility layout. However, it was estimated that 4.7 % of NVA for the side product would be reduced by redesigning the facility layout. The recommendations were suggested for the company to improve their performance. The novelty of the thesis is based on the fact that it addresses two main issues related to lean manufacturing: firstly, suggesting lean techniques based on assessment of lean profile that is based on BSC and QFD, and secondly assessing the cost effectiveness of the suggested lean methods based on LCCA and MCDM. This thesis provides a generalized model that enables the decision-maker to know and measure, holistically, the company performance with respect to customer requirements. This will enable the company to analyze the critical problems, suggest solutions, evaluate them and make a cost effective decision. Thus, the company can improve its competitiveness.</p>

Κατά την εκπόνηση της παρούσας διδακτορικής διατριβής αναπτύχθηκε μία γενικευμένη μεθοδολογία βελτιστοποίησης των διεργασιών που χρησιμοποιούνται για την παραγωγή, μορφοποίηση και συνένωση κατασκευαστικών στοιχείων από σύνθετο υλικό, με κριτήριο την ποιότητα και το κόστος του παραγόμενου προϊόντος. Στην μεθοδολογία που προτείνεται, η διάταξη και τα τεχνολογικά χαρακτηριστικά της μονάδας παραγωγής, μορφοποίησης ή συγκόλλησης των κατασκευαστικών στοιχείων θεωρούνται μεταβλητές. Επομένως, για την βελτιστοποίηση της αντίστοιχης διεργασίας με κριτήρια την ποιότητα και το κόστος του παραγόμενου προϊόντος θεωρούνται ως μεταβλητά μεγέθη τόσο οι τιμές των παραμέτρων της διεργασίας (π.χ. πίεση, θερμοκρασία, χρόνος κλπ.) όσο και η διάταξη και τα τεχνολογικά χαρακτηριστικά της σχετικής μονάδας για την εφαρμογή της διεργασίας (π.χ. διάταξη και τεχνικά χαρακτηριστικά της μονάδας θέρμανσης). Η μεθοδολογία μπορεί να εφαρμοστεί στο σύνολο των διεργασιών που χρησιμοποιούνται στα θερμοπλαστικά σύνθετα υλικά και ευκολότερα σε διεργασίες στις οποίες είναι δυνατή η άμεση επιλογή των παραμέτρων της διεργασίας και η μεταβολή των διατάξεων της χρησιμοποιούμενης συσκευής∙ βασίζεται στην θεώρηση ότι σημαντικός παράγοντας που επηρεάζει το κόστος καθώς και την ποιότητα του παραγόμενου προϊόντος είναι ο κύκλος θέρμανσης που θα επιλεγεί. Η προτεινόμενη μεθοδολογία περιλαμβάνει την πειραματική διερεύνηση της επίδρασης των παραμέτρων της διεργασίας και ειδικότερα του κύκλου θέρμανσης στα προκαθορισμένα χαρακτηριστικά ποιότητας του παραγόμενου προϊόντος (π.χ. κρίσιμες μηχανικές ιδιότητες) καθώς και συσχέτιση των παραπάνω παραμέτρων με το τελικό κόστος παραγωγής, χρησιμοποιώντας την μεθοδολογία της εκτίμησης κόστους με βάση τη δραστηριότητα (Activity Based Costing method). Από την παραπάνω διερεύνηση προκύπτουν οι συναρτήσεις ποιότητας, οι οποίες κυρίως από το υλικό που χρησιμοποιείται, και οι συναρτήσεις εκτίμησης κόστους, οι οποίες εξαρτώνται κυρίως από την διεργασία. Σε κάποιες περιπτώσεις, τα πειραματικά δεδομένα που απαιτούνται για τον προσδιορισμό των παραπάνω συναρτήσεων είναι διαθέσιμα, κυρίως από την βιομηχανία. Για την εφαρμογή της μεθοδολογίας στις περιπτώσεις που δεν είναι διαθέσιμα επαρκή πειραματικά δεδομένα, γίνεται προσομοίωση του κύκλου θέρμανσης με χρήση της μεθόδου των πεπερασμένων στοιχείων, με την βοήθεια της οποίας κατασκευάζονται παραμετρικά μοντέλα, όπου εφαρμόζεται ‘εικονικά’ ένας μεγάλος αριθμός διαφορετικών κύκλων θέρμανσης και υπολογίζονται τα θερμικά μεγέθη που αντιστοιχούν στον καθένα (χρόνος και ρυθμός θέρμανσης, θερμοκρασία υλικού και κατανομή αυτής κλπ.). Τα μεγέθη αυτά αξιοποιούνται στην συνέχεια για τον υπολογισμό των μεγεθών ποιότητας και του κόστους κάνοντας χρήση των Συναρτήσεων Ποιότητας και των Συναρτήσεων Εκτίμησης Κόστους αντίστοιχα. Ο βέλτιστος συνδυασμός των παραμέτρων της διεργασίας και του κύκλου θέρμανσης καθώς και των ορίων που μπορούν να κυμαίνονται αυτά ώστε να ικανοποιείται η απαίτηση για την εξασφάλιση των προκαθορισμένων χαρακτηριστικών ποιότητας με το μικρότερο δυνατό κόστος, προκύπτει μέσω μιας επαναληπτικής διαδικασίας βελτιστοποίησης. Για την εφαρμογή της παραπάνω μεθοδολογίας βελτιστοποίησης αναπτύχθηκε και προτείνεται ένα υπολογιστικό εργαλείο-λογισμικό, το LTSM-OPT (Laboratory of Technology and Strength of Materials Process Optimization Tool). Η προτεινόμενη μεθοδολογία εφαρμόστηκε σε δύο νέες διεργασίες που χρησιμοποιούνται στα θερμοπλαστικά σύνθετα υλικά, την διεργασία ‘ψυχρής’ μορφοποίησης με διάφραγμα (‘cold’ diaphragm forming) και την διεργασία συγκόλλησης με λέιζερ (laser transmission welding). Στο πλαίσιο αυτό, ο κύκλος θέρμανσης, που περιλαμβάνεται και στις δύο υπό εξέταση διεργασίες, προσομοιώθηκε με την βοήθεια πεπερασμένων στοιχείων με σκοπό την ‘εικονική’ εφαρμογή των αντίστοιχων κύκλων θέρμανσης στο υλικό που εξετάστηκε. Στην συνέχεια, χρησιμοποιώντας το λογισμικό LTSM-OPT, προσδιορίστηκαν οι βέλτιστες παράμετροι των παραπάνω διεργασιών και οι αντίστοιχοι κύκλοι θέρμανσης για την παραγωγή του θόλου ελικοπτέρου καθώς και για την συγκόλληση ενισχυτικών δοκών στο εσωτερικό μέρος της ατράκτου αεροσκαφών, αντίστοιχα. Τα αποτελέσματα που προέκυψαν από την εφαρμογή της προτεινόμενης μεθοδολογίας αξιολογήθηκαν και χρησιμοποιήθηκαν από την εταιρεία κατασκευής ελικοπτέρων EUROCOPTER και την εταιρεία κατασκευής αεροσκαφών AIRBUS για την εγκατάσταση μίας νέας μονάδας ‘ψυχρής’ μορφοποίησης με διάφραγμα και την παραγωγή πρωτοτύπων θόλων ελικοπτέρου, καθώς και για την ρύθμιση της διάταξης του υπάρχοντος συστήματος συγκόλλησης με λέιζερ διόδου και την συγκόλληση ενισχυτικών δοκών στην άτρακτο αεροσκαφών, αντίστοιχα. / In the framework of the current PhD thesis, a generic concept for the optimization of manufacturing processes of composite material components with regard to product’s quality and cost is introduced. In the proposed concept the configuration of the manufacturing unit is considered as an option for optimizing families of products with regard to quality and cost. For processes offering flexibility in selecting process features and parameters, the concept can be applied straight forward. The proposed concept relies on the consideration of the processes thermal cycle as essential for both the quality and cost of the produced part. It involves a quality sensitivity analysis based on experimental data, which relates the values of the thermal cycle parameters to predefined quality characteristics (e.g. critical mechanical properties) as well as a cost analysis by relating the parameters of the thermal cycle to cost data using the Activity Based Costing (ABC) methodology. Outcome of the above analyses is the derivation of the material dependent Quality Functions (QFs) along with the derivation of the process dependent Cost Estimation Relationships (CERs). The configuration of the manufacturing unit is considered as an option for optimizing families of products with regard to quality and cost. To achieve this, the heating process has been simulated by developing a parametric Finite Element model, so as to virtually conceive heating units and calculate the corresponding thermal cycles. The latter are exploited to calculate quality and cost values using the derived QFs and CERs. The optimal thermal cycle which leads to minimum cost that satisfies the design and quality requirements, along with the allowable thermal cycle windows, is derived, by involving an iterative optimization procedure. To carry out the optimization procedure a suitable software tool, the LTSM-OPT tool, is developed and introduced. The proposed concept has been applied to optimize the ‘cold’ Diaphragm Forming (CDF) process, as well as, the Laser Transmission Welding process (LTW). The thermal sub-process involved in the processes under consideration is numerically simulated such as to allow for the virtual application of the respective thermal cycle on the material. Using the developed software the features of the CDF heating system and the LTW system configuration along with the optimal thermal cycle for producing a helicopter canopy as well as for welding stiffeners on the aircraft fuselage skin, respectively, were obtained. The results of the first study were successfully exploited by EUROCOPTER to install a new flexible CDF facility and produce helicopter canopies by applying the derived optimal thermal cycle. As well, the results of the latter analysis were successfully exploited by AIRBUS to configure and adapt a laser diode source device to weld stiffeners and riblets to the aircraft fuselage skin, and thus produce integral aeronautic structures, by applying the optimized solution derived from the present study.