The increasing focus on sustainability is pushing companies to update their production systems. These systems need to facilitate the production of products with the latest sustainable technologies and innovations, while also producing these new products with lower environmental impact. To maintain high customer satisfaction, these systems must consistently deliver high-quality products. However, current quality management approaches, focused on minimal variations, might hinder this shift. Zero Defect Manufacturing (ZDM), an emerging quality approach, leverages Artificial Intelligence (AI) to monitor products and processes in real-time, allowing for early defect detection and prevention. Many production systems generate vast amounts of data which is often not used to its full potential. Research shows that AI has the potential to unlock the hidden insights within this data, leading to transformative improvements in quality and overall efficiency. However, successfully adopting AI-driven ZDM requires expertise in AI and production while also overcoming technological and organizational challenges. The purpose of this licentiate thesis is to investigate the adoption of AI-driven ZDM in production systems, examining its impacts, challenges, and facilitators during the development process. The research involved collaboration with a company producing transmission components for the heavy-duty automotive industry. A two-year case study was conducted, enabling the in-depth exploration of data throughout the development of four real-world AI-driven ZDM applications in a production system. This approach provided valuable insights into the practicalities of adopting AI to ensure ZDM. The findings show that successful implementation requires specific prerequisites: lean manufacturing practices lay the groundwork for AI integration, a high-impact quality issue motivates investment and data collection, collaboration among diverse experts is crucial, and robust IT capabilities ensure smooth data storage and analysis. Furthermore, anomaly-detection AI models and the generation of "plausible defects" are key enablers for overcoming data limitations in complex defect detection. The study emphasizes the importance of early engagement to identify data needs, define extraction methods, and address potential implementation limitations. In addition, it recommends an iterative approach to continuously improving the solution and incorporating feedback throughout the process. This comprehensive approach can pave the way for a future of sustainable manufacturing, leading to significant cost savings and increased customer satisfaction.

Sammanfattning    Detta arbete syftar till att hitta kreativa lösningar för att minimera möbelindustrins spill. Hållbarhet ur ett miljöperspektiv är ett ledord under hela studien. Jag har besökt tre svenska möbeltillverkare; Bröderna Wigells, Swedese och Karl Andersson & Söner för att undersöka hur deras tillverkningsprocess ser ut samt hur mycket spill som genereras beroende på produktionens omfattning. Detta för att sedan kunna skapa en bild av hur det ser ut i möbelindustrin och samtidigt sätta i gång den kreativa processen av att undersöka vilka eller vad man kan vidareutveckla dessa ämnen till i potentiellt nya produkter/möbler.    Min ingång i det här projektet är att eventuellt förlänga träråvarans livslängd och minska påverkan på klimatet genom att skapa produkter/möbler av redan avverkat skogsmaterial till skillnad från att köpa nytt material.    Undersökningen kommer börja med att sortera och kategorisera spillet utefter storlek samt skissa på förädlingssätt. Därefter kommer jag att undersöka ett par metoder som man på ett rationellt sätt kan bearbeta och förvandla vanligt förekommande spillmaterial till nytt användbart material och produkter som kan vara ett resultat av spillet.    Som resultat kommer jag visa upp ett omfång av produkter som kan skapas av rent spillmaterial. / Abstract    This work aims to in a creative way rediscover ways in how we can minimize wood waste in wood furniture factories and smaller woodwork shops. Sustainability is a key word to this project and during the process. I have visited three different wood furniture factories in Sweden; Bröderna Wigells, Swedese and Karl Andersson & Söner to see how their manufacturing process looks like and how and where in the production line waste evolves. The amount of each product that produces is also a factor to be regarded. All this is to paint me a picture of what the wood industry in Sweden looks like and to start a creative journey to see how you can transform these pieces of wood into new products/furniture’s. The study starts off with categorizing the wood based on size and then sketch on ways to develop these into processable pieces. Further on in this study I will investigate a series of ways to develop these pieces of wood waste constructively, becoming new subjects that can be processed in machines or brand-new furniture.     I hope that this study can contribute to prolong the lifecycle of already furniture dried wood instead of cutting down new trees. As a result of this study, I will showcase a series of furniture that has evolved from wood waste.

Den fjärde industriella revolutionen påverkar både ny och gammal teknik. Konceptet innebär en strävan att uppnå en smart fabrik genom en total uppkoppling av produktionen. Även om inte företagen kan adaptera ett fullt koncept enligt industri 4.0, har kommunikationstekniken utvecklats för att kunna användas inom dess ramar, likväl utanför. Företaget Elektroautomatik i Skövde levererar helhetslösningar för robotceller, både inom och utanför konceptet för industri 4.0. Elektroautomatik vill undersöka om det kommunikationsprotokoll som de använder sig av idag (PROFINET) och dess procedur är det mest optimala för deras kommunikation mellan en Programmable Logic Controller (PLC) och en industriell robot i robotcellerna. För att jämföra och hitta procedurer används metoden experiment. Metoden innefattar fem steg som inkluderar en analys av nuläget, ett praktiskt test av konceptet från nulägesanalysen, en iterativ process där nya praktiska test identifieras från föregående resultat, och ett sammanställt resultat. Tre protokoll som kan användas har identifierats genom att studera produktmanualerna från bägge sidor av kommunikationen. När kommunikationen testades för vardera protokoll kunde slutsatsen dras att PROFINET är det mest lämpade protokollet, då de två andra hade en negativ inverkan på funktionaliteten. PROFINET är även ett protokoll som kan användas för kommunikation både inom och utanför industri 4.0. Utifrån en genomgång av kommunikationsuppläggets struktur från Elektroautomatik och en analys av programstrukturen för deras projektmall har en nulägesanalys genomförts. Nulägesanalysen indikerade att det fanns två huvudområden för kommunikationens procedur, beordning av jobb och att skicka larmtexter. Experimentmetoden användes för att iterera fram potentiella procedurer som skulle kunna vara mer effektiva. Vid experimenten övervakades också scanningstiden i PLC:n, för att se att proceduren inte skulle ha någon negativ inverkan på prestandan. Genom ett experiment upptäcktes det att det krävdes mycket för att påverka scanningstiden, jämfört med de små signaländringarna som procedurerna innebar. För beordning av jobb kunde inte av driftsäkerhetsskäl någon lämpligare procedur än dagens identifieras. Däremot kunde kringliggande funktioner i roboten som hade en stor inverkan på tidsåtgången urskiljas. Slutsatsen för att skicka larmtexter från roboten till PLC:n var att använda en fördefinierad larmlista på PLC-sidan, och att roboten skickade en byte som representerade ett index i listan. Lösningen med en fördefinierad lista resulterade i en signifikant besparing av tid, samt en stabil tidsåtgång oavsett längd på larmtexten. / The fourth industrial revolution affects both new and old technologies. The concept implies an aspiration to achieve a smart factory through a total connection of production. Even if the companies cannot adapt a full concept according to industry 4.0, communication technologies have been developed to function within its framework, as well as outside. The company Elektroautomatik in Skövde delivers comprehensive solutions for robot cells, both within and outside the concept of Industry 4.0. Elektroautomatik wants research about the communication protocol they use today (PROFINET) and its procedure to see if it is the most optimal for their communication between a Programmable Logic Controller (PLC) and an industrial robot in their robot cells. To compare and find procedures, a method called experiment is used. The method consists of five steps that include an analysis of the current state, a practical test of the concept from the current state analysis, an iterative process where new practical tests are identified from the previous one’s results, and a compiled result. Three protocols that can be used have been identified by studying the product manuals from both sides of the communication. When the communication was tested for each protocol, it could be concluded that PROFINET is the most suitable protocol, as the other two had a negative impact on the functionality. PROFINET is also a protocol that can be used for communication both within and outside industry 4.0. Based on a review of the structure for the communication setup from Elektroautomatik and an analysis of the program structure of their project template, has a current state analysis been carried out. The current state analysis indicated that there were two main areas for communication procedures, ordering of jobs and sending alarm texts. The experiment method was used to, through iteration, identify potential procedures that could be more efficient. The scan time of the PLC were also monitored during the experiments, to see that the procedure would not have any negative impact on the performance. Through an experiment, it was discovered that it required a lot more to affect the scan time, compared to the small signal changes that the procedures entailed. For ordering jobs could for operational security reasons no more suitable procedure than todays be identified. Surrounding functions in the robot that had a large impact on time consumption could however be distinguished. The conclusion for how to send an alarm text from the robot to the PLC was to use a predefined alarm list on the PLC side, and that the robot sent a byte representing an index in the list. The solution with a predefined list resulted in a significant saving of time, as well as a stable time consumption regardless of the length of the alarm text.

I och med den växande möbelindustrin har det blivit allt viktigare att fokusera på innovativa bordslösningar där montering, demontering och rekonditionering står i centrum. Genom att integrera dessa tre aspekter i design- och tillverkningsprocessen kan ett hållbart förhållningssätt främjas. Denna strategi möjliggör inte bara en längre livslängd för tillverkade bord utan underlättar även reparation och återanvändning, vilket minskar avfall och resursslöseri. Dagens pelarbord inom bordserien John beskrivs som “ohållbara” av användarna inom områden gällande montering, demontering och konstruktion. Uppdraget kommer att ta hänsyn till att utveckla det största bordet inom bordsserien John i samarbete med företaget Lundbergs Möbler. Företaget inriktar sig på träbordslösningar med fokus på cirkulär hållbarhet för offentliga miljöer. Projektet redogör tillvägagångssättet för att ta fram en bordslösning som kan säkerställa uppdragsgivarens mål och krav. Detta med hjälp av att en iterativ designprocess har följts där divergenta och konvergenta faser har applicerats. Projektet inleddes med en förstudie som syftade till att förstå konkurrenternas lösningsprinciper för olika typer av bord, med särskilt fokus på träbordslösningar. Förstudien bidrog även till att skapa förståelse för ergonomi och antropometri kopplat till användarens förmågor och begränsningar. Resultaten från förstudien användes sedan som underlag för den fortsatta design- och produktutvecklingsfasen. Utöver detta gav förstudien information om de fysiska begränsningarna som projektet behövde ta hänsyn till. Med denna grund kunde sedan idégenereringsfasen påbörjas där metoder som brainstorming och tumnagelskisser användes för att skapa en mängd olika idéer. Med hjälp av en morfologisk matris kunde fyra koncept genereras. För konstruktion och testning av olika framtagna koncept, användes CAD-teknik, Finita Element Metoden (FEM) och manuella hållfasthetsberäkningar för konceptutvärdering. Koncepten utvecklades vidare med hänsyn till kravspecifikationen samt återkoppling till företaget. Momentet upprepades till att ett slutgiltigt koncept kunde väljas. Processen avslutades med en ergonomisimulering i syfte att förstå hur användare påverkas av att lyfta olika bordsdelar samt att en prototyp och en CAD-modell skapades. / With the growing furniture industry, it has become increasingly important to focus on innovative table solutions that emphasize assembly, disassembly, and recondition. By integrating these three aspects into the design and manufacturing process, a sustainable approach can be promoted. This strategy not only extends the lifespan of the manufactured tables but also facilitates repair and reuse, reducing waste and resource consumption. Currently, the pillar tables within the John series are described by users as "unsustainable" in terms of assembly, disassembly, and construction. The project will focus on developing the largest table in the John series in collaboration with Lundbergs Möbler. The company specializes in wooden table solutions with an emphasis on circular sustainability for public environments.  The project outlines the approach to developing a table solution that meets the client's goals and requirements. This was achieved by following an iterative design process where divergent and convergent phases were applied.  The project began with a preliminary study aimed at understanding the solution principles of competitors for various types of tables, with a particular focus on wooden table solutions. The preliminary study also helped create an understanding of ergonomics and anthropometry related to the user's abilities and limitations. The results from the preliminary study were then used as a basis for the ongoing design and product development phase. Additionally, the preliminary study provided information about the physical constraints that the project needed to consider.  With this foundation, the ideation phase could then commence, using methods such as brainstorming and thumbnail sketches to generate a variety of ideas. A morphological matrix was used to generate four concepts. For the construction and testing of the different concepts, CAD technology, Finite Element Method (FEM), and manual strength calculations were used for concept evaluation. The concepts were further developed considering the specification requirements and feedback from the company. This process was repeated until a final concept was selected. The process concluded with an ergonomic simulation to understand how the users were affected by lifting different parts of the table, and a CAD model and a prototype were created.

Date: 2024-06-02 Level: Master thesis in Product and Process Development, advanced level, 30 credits. Institution: School of Innovation, Design and Engineering, Mälardalen University Authors: Hilan Faisal Abdulla, Parisa Rabizadegan Title: Production Automation-As-A-Service business models in Original Equipment Manufacturing companies (OEMs): A perspective on OEMs As Service Receivers Supervisor: Koteshwar Chirumalla, Mälardalen University Examiner: Angelina Sundström, Mälardalen University Aim: The aim of this study is to explore the approaches for the implementation of production automation and Production Automation as a Service (PAaaS) business models, followed by exploring which key factors influence OEMs to implement PAaaS business models. Research questions: RQ1: What are the approaches for implementing production automation and PAaaS business models in Original Equipment Manufacturing companies? RQ2: Which factors influence the implementation of PAaaS business models in Original Equipment Manufacturing companies? Method: Employing qualitative research, this study investigates the implementation of PAaaS business models in three large OEM companies. Data was collected through eight semi-structured interviews with key personnel involved in the manufacturing and automation processes. The analysis was conducted using thematic analysis to identify patterns and insights relevant to the implementation of PAaaS. Conclusion: Regarding the first research question, the study identified key approaches for implementing production automation and PAaaS business models in OEM companies. The approaches for implementing production automation include the adoption of Industry 4.0 principles, thorough market and technology assessments, identifying areas that can benefit from automation, structured approaches, pilot programs, continuous improvement practices, knowledge transfer, being up-to-date to advancements in automation technologies, building strong partnerships through academia, innovation hubs, and industry events, having centralized processes, leveraging benchmarking and leveraging Smart Factory Labs. The approaches for implementing PAaaS business models include having a phased integration approach, cultural shifts towards service-oriented values, strong organizational leadership, management of resistance, outsourcing, utilizing intangible assets, and establishing a robust business case. Addressing the second research question, influential factors for OEMs implementing PAaaS business models include financial flexibility, operational efficiency, availability, innovation and availability.  Challenges such as integrating with legacy systems, ensuring stable internet connectivity, and managing cybersecurity risks also play significant roles in influencing PAaaS adoption, hence tailored solutions that align with the company's specific needs are essential for successful PAaaS business models adoption.  Keywords: Production Automation, Servitization, Service-Oriented Business Models, Original Equipment Manufacturers (OEM), Industry 4.0, Manufacturing industry

ABSTRACT Date: 2nd June 2024 Level: Master thesis in Product- and Process Development, advanced level, 30 credits Institution: School of Innovation, Design and Engineering at Mälardalen University Authors: Tony Kaya  Morteza Najafi  Title: Implementation of lean tools to visualize performance and eliminate waste Supervisor:  Satyam Paul - Mälardalens University, Florian Grouset - Alstom Florian Grouset, Alstom Keywords:  Lean; Lean tools; performance management; Continuous improvement  Purpose: This study investigates how applying different lean tools can develop a dashboard that can visualize performance on the shop floor and identify and eliminate waste at the depot, thus achieving performance improvement through continuous improvement actions.  Research questions: 1. How can the Lean visual management concept visualize performance  and support continuous improvement on the shop floor?  2. How can waste be identified and eliminated to enhance the depot's performance using Lean tools? Methodology: The study is based on a qualitative and quantitative research strategy called mixed method, which follows an abductive research approach. This resulted in adjustments and obtained that provided new perspectives and insights into the known challenges. The collection of theoretical material consisted mainly of scientific articles and books, supplemented occasionally with theoretical material from websites. The empirical data collection consisted mainly of informal meetings, observations in Gemba Walk, unstructured interviews, and four semi-structured interviews with the company. Conclusion: In the study's conclusion, it was found that the Lean Visual Management concept is an excellent method for visualizing performance and supporting continuous improvement on the shop floor. It improves information flow engagement and ensures visualization of performance in terms of KPIs. Furthermore, it was found that improvement can be identified and eliminated through lean tools such as flowcharts, VSM, spaghetti diagrams, and 5S.

In today’s manufacturing industry allowing the user to customize its product has become a major trend. These types of production systems are called High-mix Low-volume or HMLV, mainly characterized by their flexibility and complex scheduling. On top of that, the competitiveness of the manufacturing industry requires these systems to function with maximum efficiency and productivity. Manufacturers face many different challenges and halting production to study them and implement a new solution is less feasible every day. A possible solution is simulating the production system with a digital twin to study it without affecting the physical system.  This project focuses on developing a Digital Twin that simulates the first stages of the production system in Norrebo, a woodworking factory that practices HMLV production. An immersive experience for the user was developed including VR systems to make the simulation much more interactive and easier to use. The project aims to study the HMLV production system, its challenges, and how to simulate those challenges using Digital Twins.

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<p>Godkänd; 2010; 20100823 (ysko); DISPUTATION Ämnesområde: Arbetsvetenskap/Human Work Science Opponent: Professor Lennart Svensson, Linköpings universitet Ordförande: Professor Jan Johansson, Luleå tekniska universitet Tid: Fredag den 22 oktober 2010, kl 09.00 Plats: F531, Luleå tekniska universitet</p>