This master’s thesis is performed at Department of Management and Engineering Linköping University, for Scania Omni at Scania Production Slupsk (S.P.S). Omni is responsible for development, manufacturing and marketing of city, suburban and intercity buses. After acquisition of the production unit in Slupsk in 2002 lower production cost per bus is possible. But without control over the organisation costs are rising due to late delivery fees and high stock levels. At the outset, the thesis included three clearly defined objectives: - Map the present situation at Scania Production Slupsk regarding material flow from supplier to assembly line including a part and storage analysis. - Benchmark the current routines at Scania Production Slupsk with other successful companies. Furthermore, conduct literature research in order to find theories and philosophies that support problem analysis and thesis solution. - Develop standard routines for material control methods (MCM) and material supply methods (MSM). A complimentary objective is to work as a catalyst during the time of the thesis. The mapping of the present situation showed that MCM and MSM are very tight connected to each other. It was questioned whether this structure was the best way to manage the material flow. After a parts and storage analysis, material was divided into different segments depending of price, consumption and movement. The benchmarking studies showed different ways to manage the material flow. Implementation of unit load, kanban and clear defined interface between departments showed potential to improve the material handling and increase effectiveness. New routines and part segment definitions described in a logistics manual (Appendix I) were made align with a comparison between previous and recommended definitions. The result showed that some parts needs to be controlled differently. Primary recommendations are that logistics manual shall be used when new parts are introduced into the Scala system. Responsible personnel are suppose to give suggestion concerning decision making of MCM and MSM and with help of the logistics manual the work can be more efficient, resulting in a material flow that is flexible and have potential for improvements. Secondary, to avoid material handling to some extent implementation of two-bin system is recommended. Additional recommendations regarding two-bin system is to handle material according to unit load, which enable FIFO, traceability and higher turn over rate

<p>This master’s thesis is performed at Department of Management and Engineering Linköping University, for Scania Omni at Scania Production Slupsk (S.P.S). Omni is responsible for development, manufacturing and marketing of city, suburban and intercity buses. After acquisition of the production unit in Slupsk in 2002 lower production cost per bus is possible. But without control over the organisation costs are rising due to late delivery fees and high stock levels. At the outset, the thesis included three clearly defined objectives:</p><p>- Map the present situation at Scania Production Slupsk regarding material flow from supplier to assembly line including a part and storage analysis.</p><p>- Benchmark the current routines at Scania Production Slupsk with other successful companies. Furthermore, conduct literature research in order to find theories and philosophies that support problem analysis and thesis solution.</p><p>- Develop standard routines for material control methods (MCM) and material supply methods (MSM).</p><p>A complimentary objective is to work as a catalyst during the time of the thesis.</p><p>The mapping of the present situation showed that MCM and MSM are very tight connected to each other. It was questioned whether this structure was the best way to manage the material flow. After a parts and storage analysis, material was divided into different segments depending of price, consumption and movement. </p><p>The benchmarking studies showed different ways to manage the material flow. Implementation of unit load, kanban and clear defined interface between departments showed potential to improve the material handling and increase effectiveness.</p><p>New routines and part segment definitions described in a logistics manual (Appendix I) were made align with a comparison between previous and recommended definitions.</p><p>The result showed that some parts needs to be controlled differently. Primary recommendations are that logistics manual shall be used when new parts are introduced into the Scala system. Responsible personnel are suppose to give suggestion concerning decision making of MCM and MSM and with help of the logistics manual the work can be more efficient, resulting in a material flow that is flexible and have potential for improvements.</p><p>Secondary, to avoid material handling to some extent implementation of two-bin system is recommended. Additional recommendations regarding two-bin system is to handle material according to unit load, which enable FIFO, traceability and higher turn over rate</p>

Syfte – Syftet med denna studie är att undersöka hur materialhantering från inleverans till förmontering i ett tillverkande företag av kundanpassade produkter kan förbättras med avseende på kvalitet. Följande två frågeställningar ska uppfyllas för att besvara syftet: 1. Vilka faktorer påverkar materialhanteringen från inleverans fram till förmontering? 2. Hur kan faktorerna förbättras för att erhålla en effektiv materialhantering från inleverans fram till förmontering? Metod – En fallstudie genomfördes på ett företag inom husvagnsindustrin för att samla in empiriskt material. Intervjuer och observationer användes under fallstudien. Vidare genomfördes en litteraturstudie för att skapa ett teoretiskt ramverk. Den insamlade datan jämfördes och analyserades gentemot det teoretiska ramverket. Resultat – Flera faktorer som påverkar materialhanteringen har identifierats. Dessa var mänskliga faktorer och av Liker’s (2009) åtta slöserier var det sex stycken som identifierades. Flera potentiella förbättringsförslag rekommenderas till att förbättra respektive faktor. Några av förslagen till en mer effektiv materialhantering är bättre kommunikation och kontroll, standardiserade arbetsmoment samt implementering av periodinspektionssystem. Genom bättre samverkan mellan anställda kan bättre förståelse till varandras processer skapas vilken kan leda till att anställdas kompetens utnyttjas. Implikationer – Studien har visat på flera olika faktorer som påverkar materialhanteringen. Förbättringsförslagen som har rekommenderats till att effektivisera materialhanteringen är utav olika karaktärer vilken gör att implementationer kan vara både enkla och svåra. Det är viktigt att företag identifierar sina egna påverkande faktorer när de ska effektivisera materialhanteringen. Begränsningar – Under datainsamlingen har en enfallsstudie med en analysenhet genomförts. Dock kan en flerfallsstudie genomföras i syfte att generalisera studiens resultat ytterligare. Vidare har fokus varit från inleverans fram till förmontering. Detta har begränsat arbetet från andra avdelningar som kan ge andra perspektiv på materialhanteringen. / Purpose – The purpose of this study is to examine how the material handling from receiving to pre-assembly of a manufacturing company of customized products can be improved in terms of quality. The following two issues must be met in order to answer the purpose: 1. What factors influence the material handling from receiving until the pre-assembly? 2. How can the factors be improved to obtain an effective material handling from receiving until the pre-assembly? Method – A case study was conducted at a company in the caravan industry in order to gather empirical material. Interviews and observations were executed during the case study. Further on, a literature study was conducted to create a theoretical framework. The collected data was compared and analyzed against the theoretical framework. Findings – Several factors that affect the material handling have been identified. These were human factors and from Liker´s (2009) eight wastes were six identified. Several potential improvement methods were suggested for each factor. Some of the proposed improvement methods for a more efficient material handling is better communication and control, standardized operations and implementation of periodic inspection system. Through better collaboration between employees, a better understanding of each other's processes can generate a better use of their expertise. Implications – The study has revealed several factors that affect the material handling. Suggestions that have been recommended for improving the efficiency of material handling are based of different nature which means that the implementations can both be easy and difficult. It is important that companies identify their own influencing factors when they are going to improve the efficiency of material handling. Limitations – During the data collection, a single-case study with one analyzing unit was performed. However, a multi-case study can be performed in order to further generalize the results from the study. Furthermore, the focus has been from receiving until the pre-assembly. This has limited the work from other departments that can provide a different perspective on material handling.

In order to be competitive, one way is to focus on the internal logistics in a cost effective manner. The concept of material control covers how to control the flow of material resources from the customer to the supplier. This study intends to look at how internal material control can be done efficiently in a manufacturing company. In order to achieve an efficient internal material control, methods and approaches should be evaluated based on a situational approach. Therefore, the purpose of the study is to develop a model for analysis and improvement of internal material control in manufacturing companies. The study is a case study and has been conducted on site at Atlas Copco Tierp Works. Atlas Copco in Tierp, produces components and assembles hand-held power tools. The empirical data has been conducted with employees at Atlas Copco Tierp Works and with direct observations of the processes that the study has been limited to. Literature reviews have been made in parallel with the empirical data collection with an emphasis on internal logistics, material control and lean production. The study shows which factors that are important for an effective internal material control. Furthermore, the report presents an analysis model, which has been applied to Atlas Copco Tierp Works. The analysis model presents a recommendation on appropriate material planning method, as well as the conditions that should be complied in order to achieve an efficient internal material control. The analysis model strengths are considered as mainly to be that it covers many areas, by including the planning environment, material planning methods, efficiency and decision-making. Accordingly, the model is considered to have potential for development by including a cost analysis as a part of the decision-making part. / Att styra sin interna logistik, på ett kostnadseffektivt sätt, är en nödvändighet för att kunna konkurrera på en redan hårt utsatt marknad. Materialstyrning kan ses som en delmängd av logistik och innefattar aktiviteter för att styra och planera materialflödet från leverantör till kund. Denna studie visar på hur den interna materialstyrningen kan ske effektivt, i ett tillverkande företag. För att uppnå en effektiv intern materialstyrning så bör metoder och tillvägagångssätt utvärderas utifrån ett situationsanpassat synsätt. Studiens syfte är därför att utveckla en modell för analys och förbättring av intern materialstyrning i tillverkande företag. Fallstudien har bedrivits vid Atlas Copco Tierpverken. Vid fabriken i Tierp sker tillverkning av komponenter samt montering av handhållna industriverktyg. Den empiriska datainsamlingen har skett genom intervjuer med medarbetare på Tierpverken och observationer över det interna materialflödets processer som studien avgränsat sig till. En litteraturundersökning har gjorts, med betoning på intern logistik, materialstyrning och Lean Production. Studien visar vilka faktorer som är av betydelse för en effektiv intern materialstyrning. Rapporten presenterar en analysmodell, vilken har tillämpats på Atlas Copco Tierpverken. Analysmodellen ger en rekommendation på lämplig materialstyrningsmetod, samt vilka förutsättningar som bör uppfyllas för att uppnå en effektiv intern materialstyrning.  Analysmodellens styrkor anses främst vara att den täcker in många områden, där planeringsmiljö, materialstyrningsmetoder, effektivitet inkluderas för att beslut och rekommendationer kan utföras. Modellen bedöms ha utvecklingspotential genom att inkludera en kostnadsanalys som en del vid beslut.

Safeguards and security (S&S) systems for nuclear facilities include material control and accounting (MC&A) and a physical protection system (PPS) to protect nuclear materials from theft, sabotage and other malevolent human acts. The PPS for a facility is evaluated using probabilistic analysis of adversary paths on the basis of detection, delay, and response timelines to determine timely detection. The path analysis methodology focuses on systematic, quantitative evaluation of the physical protection component for potential external threats, and often calculates the probability that the PPS is effective (PE) in defeating an adversary who uses that attack path. By monitoring and tracking critical materials, MC&A activities provide additional protection against inside adversaries, but have been difficult to characterize in ways that are compatible with the existing path analysis methods that are used to systematically evaluate the effectiveness of a site’s protection system. This research describes and demonstrates a new method to incorporate MC&A protection elements explicitly within the existing probabilistic path analysis methodology. MC&A activities, from monitoring to inventory measurements, provide many, often recurring opportunities to determine the status of critical items, including detection of missing materials. Human reliability analysis methods are applied to determine human error probabilities to characterize the detection capabilities of MC&A activities. An object-based state machine paradigm was developed to characterize the path elements and timing of an insider theft scenario as a race against MC&A activities that can move a facility from a normal state to a heightened alert state having additional detection opportunities. This paradigm is coupled with nuclear power plant probabilistic risk assessment techniques to incorporate the evaluation of MC&A activities in the existing path analysis methodology. Event sequence diagrams describe insider paths through the PPS and also incorporate MC&A activities as path elements. This work establishes a probabilistic basis for incorporating MC&A activities explicitly within the existing path analysis methodology to extend it to address insider threats. The analysis results for this new method provide an integrated effectiveness measure for a safeguards and security system that addresses threats from both outside and inside adversaries. / text

<p>Ett centralt processteg för sågverk är att sönderdela stockar med olika sågmönster. Vid sönderdelning uppstår ett visst råvaruspill, men genom att använda rätt sågmönster till varje enskild stock kan detta spill minimeras. Som ett steg i att göra detta försorteras därför timmer i ett antal timmerklasser som samlar stockar med liknande egenskaper. Råvarustyrning innebär att välja vilka mönster varje klass ska sågas med, hur stor andel av varje klass som ska sågas med dessa mönster samt att bestämma hur stockar sorteras till klasserna.</p><p>I detta arbete utvecklas ett optimeringsverktyg som angriper problemet att optimera råvarustyrningen med avseende på de framställda produkternas försäljningsvärde. Problemet delas upp i två nivåer där linjärprogrammering kan användas i den ena nivån med syfte att, givet en uppsättning klasser, optimera valen av sågmönster. Linjärprogrammering används eftersom kubikmeterpriset på de sågade trävarorna antas vara konstant med avseende på producerad volym. Den andra problemnivån innebär att optimera timmersorteringen och för detta ändamål implementeras och utvärderas fyra lokalsökningsalgoritmer.</p><p>Genom ett gränssnitt mot användare och databaser kan sågverk ladda in timmerdata, simulerade produktutfall när timmer sågas med olika sågmönster, samt lägsta och högsta tillåtna produktvolymer. Utöver optimering av råvarustyrning kan optimeringsverktyget användas som stöd för att skapa väl underbyggda kundofferter vid nya orderingångar eller väntade förändringar av råvarufördelning.</p><p>Optimeringsverktyget klarar alltid av att hitta det optimala valet av postningar och postningsandelar givet en uppsättning klasser om det existerar minst <em>ett</em> val som uppfyller bivillkoren på framställda produktvolymer. Emellertid visar tester att denna beräkningsrutin gör anspråk på för mycket tid, men sannolikt kan den effektiviseras tillräckligt mycket för att användas skarpt i praktiken. Den bästa lokalsökningsalgoritmen fungerar tillfredsställande i tester, men det krävs mer utvecklingsarbete för att den ska rubriceras som helt klar. Främst i form av att möjliggöra för algoritmen att finna en lösning om sågverkets grundinställda klasser inte kan uppfylla bivillkoren på produktvolymer.Testdatat som används kommer från ett verkligt sågverk, men på grund av brister i detta data kan inga slutsatser dras angående ökad lönsamhet för sågverket genom användning av optimeringsverktyget.</p> / <p>A key process step in sawmills is the sawing of logs into wood, using various sawing patterns. A certain amount of waste always results when sawing, but by using the right sawing pattern for each individual log this waste can be minimized. One way to address this is to presort the incoming logs into a number of sawing classes, where all of these collect logs with similar properties. Raw material control at sawmills involves choosing the patterns to be used on each class, the share of each class to be sawn with the various patterns and also deciding the way logs are assigned to the sawing classes.</p><p>In this work an optimization tool is constructed that addresses the problem of optimizing the raw material control with respect to the sales value of the manufactured products. The problem is divided into two sub-problems where linear programming can be used for one of these sub-problems with purpose to optimize the choices of sawing patterns given a set of classes. Linear programming can be used because the unit price of sawn goods is assumed to be constant with respect to the volume produced. The second sub-problem is to optimize the sorting of logs and in order to do this four different local search algorithms are implemented and evaluated.</p><p>Through an user and database interface the sawmill can access sawlog data, simulated product outcomes and constraints for product volumes. In addition to optimization of the raw material control the optimization tool can help the user to create well-founded quotations whenever new orders arrive or the anticipated raw material distribution changes.</p><p>The optimization tool always manages to find the optimal choice of sawing patterns and shares for a set of sawing classes given the existence of at least one choice that fulfills the constraints for manufactured product volumes. Tests show however, that this computational step requires too much time, but it can probably be streamlined enough to be used in practice.The best local search algorithm serves satisfactory in tests, but needs more development in order to be labeled as finished. Foremost by enabling the algorithm to find a solution even if the sawmill's default sawing classes can not fulfill the product volume constraints. The test data used when evaluating the algorithms come from a real sawmill, but due to shortcomings in the data no conclusions about increased profit for the sawmill can be drawn.</p>

Ett centralt processteg för sågverk är att sönderdela stockar med olika sågmönster. Vid sönderdelning uppstår ett visst råvaruspill, men genom att använda rätt sågmönster till varje enskild stock kan detta spill minimeras. Som ett steg i att göra detta försorteras därför timmer i ett antal timmerklasser som samlar stockar med liknande egenskaper. Råvarustyrning innebär att välja vilka mönster varje klass ska sågas med, hur stor andel av varje klass som ska sågas med dessa mönster samt att bestämma hur stockar sorteras till klasserna. I detta arbete utvecklas ett optimeringsverktyg som angriper problemet att optimera råvarustyrningen med avseende på de framställda produkternas försäljningsvärde. Problemet delas upp i två nivåer där linjärprogrammering kan användas i den ena nivån med syfte att, givet en uppsättning klasser, optimera valen av sågmönster. Linjärprogrammering används eftersom kubikmeterpriset på de sågade trävarorna antas vara konstant med avseende på producerad volym. Den andra problemnivån innebär att optimera timmersorteringen och för detta ändamål implementeras och utvärderas fyra lokalsökningsalgoritmer. Genom ett gränssnitt mot användare och databaser kan sågverk ladda in timmerdata, simulerade produktutfall när timmer sågas med olika sågmönster, samt lägsta och högsta tillåtna produktvolymer. Utöver optimering av råvarustyrning kan optimeringsverktyget användas som stöd för att skapa väl underbyggda kundofferter vid nya orderingångar eller väntade förändringar av råvarufördelning. Optimeringsverktyget klarar alltid av att hitta det optimala valet av postningar och postningsandelar givet en uppsättning klasser om det existerar minst ett val som uppfyller bivillkoren på framställda produktvolymer. Emellertid visar tester att denna beräkningsrutin gör anspråk på för mycket tid, men sannolikt kan den effektiviseras tillräckligt mycket för att användas skarpt i praktiken. Den bästa lokalsökningsalgoritmen fungerar tillfredsställande i tester, men det krävs mer utvecklingsarbete för att den ska rubriceras som helt klar. Främst i form av att möjliggöra för algoritmen att finna en lösning om sågverkets grundinställda klasser inte kan uppfylla bivillkoren på produktvolymer.Testdatat som används kommer från ett verkligt sågverk, men på grund av brister i detta data kan inga slutsatser dras angående ökad lönsamhet för sågverket genom användning av optimeringsverktyget. / A key process step in sawmills is the sawing of logs into wood, using various sawing patterns. A certain amount of waste always results when sawing, but by using the right sawing pattern for each individual log this waste can be minimized. One way to address this is to presort the incoming logs into a number of sawing classes, where all of these collect logs with similar properties. Raw material control at sawmills involves choosing the patterns to be used on each class, the share of each class to be sawn with the various patterns and also deciding the way logs are assigned to the sawing classes. In this work an optimization tool is constructed that addresses the problem of optimizing the raw material control with respect to the sales value of the manufactured products. The problem is divided into two sub-problems where linear programming can be used for one of these sub-problems with purpose to optimize the choices of sawing patterns given a set of classes. Linear programming can be used because the unit price of sawn goods is assumed to be constant with respect to the volume produced. The second sub-problem is to optimize the sorting of logs and in order to do this four different local search algorithms are implemented and evaluated. Through an user and database interface the sawmill can access sawlog data, simulated product outcomes and constraints for product volumes. In addition to optimization of the raw material control the optimization tool can help the user to create well-founded quotations whenever new orders arrive or the anticipated raw material distribution changes. The optimization tool always manages to find the optimal choice of sawing patterns and shares for a set of sawing classes given the existence of at least one choice that fulfills the constraints for manufactured product volumes. Tests show however, that this computational step requires too much time, but it can probably be streamlined enough to be used in practice.The best local search algorithm serves satisfactory in tests, but needs more development in order to be labeled as finished. Foremost by enabling the algorithm to find a solution even if the sawmill's default sawing classes can not fulfill the product volume constraints. The test data used when evaluating the algorithms come from a real sawmill, but due to shortcomings in the data no conclusions about increased profit for the sawmill can be drawn.

This master thesis was performed in collaboration with Scania Ferruform in Luleå, with the purpose to create an efficient, rational and safe workplace at the unloading station of the crossmember painting line. The mission from Ferruform was to investigate and analyse flaws, risk, and bottlenecks with regards to flows, ergonomics and material handling. The project aimed to create a vision that could guide present and future development, followed by an implementation strategy consisting of concrete measures of both layout and organisational character. The vision is: “Create a work situation that is rooted in Scania's production system and characterized by efficiency, rationality and safe working conditions, where committed individuals can be challenged and developed”   The research questions that has guided the project are: What problem is the basis for the ergonomic situation at the crossmember painting? How can an efficient and rational workplace be created at crossmember painting? What does Ferruform need to do to create a safe and sustainable work environment at the crossmember painting?   The first step was to map the current state and identify problems with regards to process and organisation. This was done by using participative observation, interviews, user participation, overview analysis and Scania’s intranet. Apart from previous studies, the main problems that the mapping identified was consequences of frequent downtimes, shifts being isolated and having unique work methods, unsafe work environment, and finally that tools and aids for reducing harmful lifts are not used.  These problems and their consequences were analysed with regards to the current research in work science, behavioural science, and by using methods such as Fault tree analysis and proximity chart. One of the most important conclusions was that downtime, apart from compromised production volumes, affected the work situation negatively. Operators compensate for downtime by working faster and unsafe to reach the weekly production goals. Additionally, a middle manager role has disappeared in favour of meeting the production goals. This has severe consequences on the organisation of work and among others, ergonomics. The proximity chart showed that placement of functions in the production system is not based on logic, resulting in safety issues, intersecting flows and inefficient handling of materials. To counter the identified problems, three different layouts were developed and evaluated using the specification of requirements. The concept with highest score was further developed and detail designed. It is called “Wing” and separates humans and forklifts, has a centralized material buffer and redundancy for downtime. The concept allows for safer work environment, and efficient flows. The required changes are arranged in three steps, each with increasing capacity. The final concept together with the implementation plan, which present recommendations on how the final concept could gradually be implemented and what organisational changes that are needed, shows that productivity and rationality can coexist with a good work environment, where both humans and the production system can flourish.

El tema de este trabajo de suficiencia profesional es la comparación de la Planificación de Requerimientos de Materiales Guiada por la Demanda del Mercado (DDMRP por su nombre en inglés: Demand Driven Material Requirements Planning), con los métodos de planificación tradicionales. De esta forma, la pregunta de investigación propuesta apunta a conocer si la DDMRP tiene un mejor desempeño que las técnicas de Planificación de los Materiales (MRP por su nombre en inglés: Material Requirements Planning), MRPII (por su nombre en inglés: Material Requirements Planning II) y Kanban. La presente investigación está guiada por tres objetivos, cada uno desarrollado en un capítulo aparte: el primero de ellos identifica los tipos de métodos de planificación y control de materiales y sus características; el segundo propone las ventajas y desventajas de la implementación de los métodos de planificación y control de materiales (Kanban, MRP, MRP II y DDMRP); y el tercero enumera los factores que contribuyen al éxito o fracaso de los métodos de planificación y control de materiales (Kanban, MRP, MRP II y DDMRP). Finalmente, se presentan los resultados, las conclusiones a las que se ha llegado y las recomendaciones. / The subject of this professional sufficiency paper is the comparison of Demand Driven Material Requirement Planning (DDMRP) with traditional planning methods. Thus, the research question posed refers to knowing if DDMRP has a better performance than MRP, MRPII and Kanban techniques. This research is divided into three objectives; the first one identifies the types of materials planning and control methods and their characteristics; the second develops the advantages and disadvantages of implementing materials planning and control methods such as Kanban, MRP, MRP II and DDMRP; and the third objective lists the factors that contribute to the success or failure of materials planning and control methods such as such as Kanban, MRP, MRP II and DDMRP. Finally, the results, conclusions reached and recommendations are presented. / Trabajo de Suficiencia Profesional