<p>The purpose of this study was to examine and evaluate an assembly station at Kalmar Industries in respect to ergonomics. The study was to result in an improved assembly station with lower risk of work- related injuries. It was the study group’s expectation that the measures taken at the assembly station can function as guidance and an inspiration for other ergonomic improvements at the company. Several goals related to the purpose were established as guidance for the study.</p><p>The mechanic’s work situation was mapped through a series of methods. With inquiry and interviews the study group got information of the mechanics own thoughts, ideas and understanding about the working situation. Application of participating and non-participating observation, photographing and video filming gave the project members the possibility to document the reality and compare it with gathered information from the mechanics. At the same time, literature and earlier studies was studied to gather current information and ideas.</p><p>All data was analyzed and parallel to this several solutions could be developed by the study group with the help of innovation techniques and benchmarking. The solutions are composed of recommendations on purchases and new product development for improvements in respect to the ergonomic situation.</p>

The purpose of this study was to examine and evaluate an assembly station at Kalmar Industries in respect to ergonomics. The study was to result in an improved assembly station with lower risk of work- related injuries. It was the study group’s expectation that the measures taken at the assembly station can function as guidance and an inspiration for other ergonomic improvements at the company. Several goals related to the purpose were established as guidance for the study. The mechanic’s work situation was mapped through a series of methods. With inquiry and interviews the study group got information of the mechanics own thoughts, ideas and understanding about the working situation. Application of participating and non-participating observation, photographing and video filming gave the project members the possibility to document the reality and compare it with gathered information from the mechanics. At the same time, literature and earlier studies was studied to gather current information and ideas. All data was analyzed and parallel to this several solutions could be developed by the study group with the help of innovation techniques and benchmarking. The solutions are composed of recommendations on purchases and new product development for improvements in respect to the ergonomic situation.

<p>The purpose of this study was to examine and evaluate an assembly station at Kalmar Industries in respect to ergonomics. The study was to result in an improved assembly station with lower risk of work- related injuries. It was the study group’s expectation that the measures taken at the assembly station can function as guidance and an inspiration for other ergonomic improvements at the company. Several goals related to the purpose were established as guidance for the study.</p><p>The mechanic’s work situation was mapped through a series of methods. With inquiry and interviews the study group got information of the mechanics own thoughts, ideas and understanding about the working situation. Application of participating and non-participating observation, photographing and video filming gave the project members the possibility to document the reality and compare it with gathered information from the mechanics. At the same time, literature and earlier studies was studied to gather current information and ideas.</p><p>All data was analyzed and parallel to this several solutions could be developed by the study group with the help of innovation techniques and benchmarking. The solutions are composed of recommendations on purchases and new product development for improvements in respect to the ergonomic situation.</p>

The purpose of this study was to examine and evaluate an assembly station at Kalmar Industries in respect to ergonomics. The study was to result in an improved assembly station with lower risk of work- related injuries. It was the study group’s expectation that the measures taken at the assembly station can function as guidance and an inspiration for other ergonomic improvements at the company. Several goals related to the purpose were established as guidance for the study. The mechanic’s work situation was mapped through a series of methods. With inquiry and interviews the study group got information of the mechanics own thoughts, ideas and understanding about the working situation. Application of participating and non-participating observation, photographing and video filming gave the project members the possibility to document the reality and compare it with gathered information from the mechanics. At the same time, literature and earlier studies was studied to gather current information and ideas. All data was analyzed and parallel to this several solutions could be developed by the study group with the help of innovation techniques and benchmarking. The solutions are composed of recommendations on purchases and new product development for improvements in respect to the ergonomic situation.

Rapporten behandlar utveckling av en halvautomatisk monteringsstation för en elektronisk vattenblandare. Monteringsstationen roterar blandarhuset till vattenblandaren i olika positioner så att en operatör manuellt kan montera på komponenter på blandarhuset. Nya behov har uppmärksammats under tiden monteringsstationen varit i bruk och nya sekvenser för byte av redan monterade komponenter på en färdigmonterad produkt har tagits fram. Främst handlar behovet om att kunna byta en enskild komponent på en färdigmonterad produkt när det har visat sig att den monterade komponenten inte håller måttet i kontroller direkt efter monteringsprocessen. Kartläggning av aktuella sekvenser har gjorts genom observationer när monteringsstationen i varit i bruk. För att få fram nya optimerade sekvenser har behovet av förbättringar kartlagts genom att fråga produktionstekniker och operatörer i monteringen om upplevda problem och önskemål på förändringar i monteringsstationen för att underlätta monteringsarbetet och öka motivationen. Byte av en blandventil/termostatinsats på en redan monterad vägghängd Tronic-blandare är ett av de största upplevda problemen vid monteringsstationen. En ny tidsoptimerad sekvens för byte av blandventil/termostatinsats i monteringsstationen har tagits fram som innebär att monteringsstationen kommer användas i 5 steg istället för i 10 steg som i gamla monteringssekvensen. Arbetet har även uppmärksammat vikten av att ha tillgång till aktuell programmering och dokumentation för maskiner/stationer som används i produktionen på företaget. / The report deals with the development of a semi-automatic assembly station for an electronic water mixer. The assembly station rotates the mixer housing in various positions for the operator to be able to manually assemble components on the mixer housing. The operators have identified that alternate sequences in the assembly station might improve the assembly process. New sequences for replacing already assembled components on the assembled mixer product have been developed. The main need is to be able to change a single component on an already assembled mixer product when the component has been shown not to meet the quality standards. Mapping of current sequences has been done through observations when the assembly station has been in use. To obtain new optimized sequences the need for improvements has been mapped by asking production technicians and operators in the assembly about perceived problems and wishes for changes in in the assembly station to ease the assembly work and increase motivation. Replacing a mixing valve/thermostat insert on an already assembled wall-mounted Tronic mixer is one of the biggest problems experienced at the assembly station. A new time-optimized sequence for replacing the mixing valve/thermostat insert in the assembly station has been developed. The new sequence in the assembly station will use 5 steps to finish the change instead of 10 steps as in the old sequence. The report has also highlighted the importance of having access to up-to-date programming, and documentation for machines/stations used in the production line at the company.

Modul system HH deliver modular storage systems and electrical solutions that can be combined according to the customer's wishes. This thesis combines argues for the importance for companies to keep improving their organization and production to remain competitive. By relating to a holistic view of the development of production environments, the project focuses on improvements for efficiency and social sustainability in the development of production. The project became relevant as the company has discovered difficulties in balancing production in the event of capacity changes and wants to develop rational flows and increase its flexibility. The project is limited to exploring three assembly stations and the operations and flows that belong to the assembly. The project spiral's iterative 3-step development process was chosen for strategic planning. This methodology allowed the work to continue forward despite the lack of data. The first step deals with planning and processes where technology and users were examined. In this planning phase, a Gantt schedule was used in the ClickUp program to plan the project and to-do lists and deadlines could be set. A literature study was conducted to strengthen arguments and raise new ideas. The theoretical overview focuses on areas around production development with a focus on the development of layouts/assembly stations, psychosocial work environment and organizational management. In the second phase of the project, requirements and wishes were mapped. This was done together with the company, the results from this step were then used to evaluate concepts before detailed development. The project also has several parts of the framework that Muther &amp; Wheeler developed called Systematic layout planning. It provided the tools to understand important connections through relationships and proximity analysis. These methods were also used to evaluate the results. Interviews, observations, and 3D modelling were also performed in this phase to gather information and to understand different production structures. Semi-structured interviews were performed with product managers, production designers, production planners. From these methods, I was together with some employees able to conclude that customer order-driven product development is the focus. That production places demand on rapid implementations in production and that modularity means great flexibility needs and fast lead times. We also found opportunities to minimize repetitive and time-consuming steps through development based on the operator's point of view. Concepts were developed through a development process based on proximity analysis, time studies and results from more subjective interviews. The concepts were then evaluated through an evaluation matrix based on formulated future requirements and wishes. The winning concept was developed in more detail and developed iteratively together with staff from the company. The final concept combines a new, more compact layout that considers proximity requirements between stations as well as flows of materials and operators. The final layout also introduces new types of material buffers and action proposals for improved collaboration and communication for increased flexibility.

This thesis project has been carried out with Husmuttern AB as the requestor for the job. Husmuttern AB is a company in the start-up phase which works with developing module houses which are recyclable, disassemblable and standardized. The goal for the thesis project is to design an assembly station for mobile tool boards in a Husmuttern factory. There should also be instructions for the assembly station. The tool boards are used as storage for tools, safety equipment and more. The station must be usable for people without professional experience and regardless of language knowledge and background. The research questions are: * How should the instructions be designed so that a person regardless of language background can understand them? * What are the most important factors regarding ergonomics and protection against misassembly? The method used is based on the product development process described in Produktutveckling by Ulrich, K and Eppinger, S (2012), but adapted to the current project. To obtain a complete tool board one needs to place all hooks and other storage on the board and thereafter mount the boards to legs to make it mobile. To make sure that all hooks, nuts, etc. are placed correctly, installation templates are used to show where everything needs to be placed. A fixture is used for the legs, where one stands the legs, installs the boards in the correct order and uses screws to secure them. The instructions are in the shape of a Powerpoint presentation which is displayed on TV monitors in the factory. The instructions contain pictures and video showing every step of the assembly. There are also symbols, like for example arrows, pointing out important details which need to be observed. The instructions contain no current text, the only writing is numbers, which the workers are expected to understand. The project group has carried out tests with the workers in the factory. The tests have shown that the concept works. The installation templates combined with the instructions makes it easy for the workers to understand where everything needs to be placed. The fixture for the legs has not been tested with the workers in its final form, but the concept has been tested and is working satisfactorily. / Detta examensarbete har gjorts med Husmuttern AB som uppdragsgivare. Husmuttern AB är ett företag i uppstartsfasen som utvecklar modulhus som ska vara återvinningsbara, demonterbara och standardiserade. Examensarbetet går ut på att konstruera en monteringsstation för mobila verktygstavlor till en Husmuttern-fabrik. Det ska även finnas instruktioner till stationen. Tavlorna används som förvaring för verktyg, säkerhetsattiraljer m.m. Stationen ska kunna användas av människor utan yrkeserfarenhet och oavsett språkkunskaper och bakgrund. Forskningsfrågorna är: * Hur ska instruktionerna utformas så att personer oavsett språklig bakgrund kan förstå dem? * Vilka faktorer är de mest avgörande när det gäller ergonomi och skydd mot felmontering? Metoden som använts baseras på produktutvecklingsprocessen som beskrivs i Produktutveckling av Ulrich, K och Eppinger, S (2012), men är anpassad till det aktuella projektet. För att få en färdig verktygstavla behöver man montera alla krokar och annan förvaring på tavlorna och därefter montera tavlorna på ben så att den blir mobil. För att alla krokar, muttrar m.m. ska hamna på rätt plats på tavlorna har man använt hålmallar som visar var varje del ska sitta. Till benen används en fixtur som man ställer benen i, lägger i tavlorna i rätt ordning och skruvar fast dem. Instruktionerna är i form av en powerpoint-presentation som spelas upp på tv-apparater i fabriken. Instruktionerna innehåller bilder och video som visar varje moment i monteringen. De innehåller också symboler som t.ex. pilar som ska uppmärksamma viktiga detaljer. Instruktionerna innehåller ingen löpande text, den enda skrift som finns är siffror, vilka arbetarna förväntas förstå. Projektgruppen har gjort tester med arbetare i fabriken. Testerna har visat att konceptet fungerar. Hålmallarna i kombination med instruktionerna gör att arbetarna enkelt förstår var alla delar ska monteras. Fixturen för benen har inte testats på arbetarna i sin slutgiltiga form men konceptet har testats och det fungerar tillfredsställande.

This thesis is about product and process development. The thesis has been done at ABB Robotics AB in Västerås under 20 weeks with half study pace, which is equivalent to 15 higher education credits (15hp). Thesis purpose was to improve an assembly station for assembling of robot IRB 360. Problems at the assembly station are that there are some non-value-creating activities and assembling methods which correspond to low safety factor for workers. The focus of thesis was to investigate opportunities and to produce solid proposals for how to eliminate these problems. After a written contract with ABB AB, the work started with the planning with the company supervisor and Gantt Schema was created to schedule all steps for this project, to ensure during the process. The project has followed the methods described in the book "Produktutveckling konstruktion och design " by Karl T Ulrich &amp; Steven D Eppinger. Product development tools like Quality function deployment (QFD), functional analysis, specification of requirement and Pugh's analysis matrix have been used in the development process. In the first phase of the project, observation and investigation has been performed to identify and analyse problems. In the later phases, ideas and concepts has created to solve the problems and achieve successful results. The result of the project is an improved material flow at assembling stations which eliminates nonvalue-creating activities and leads to better safety for workers. Another result of the project is an elimination of hand hammering at assembling station and for this purpose a new pressing tool has been developed for pressing down a seals around radial shaft in assembling process. The software Solidworks has been used to create a new 3D layout for the existing assembly station to understand and find the better solution for material flow. Solidworks is also used for doing Finite element method (FEM) analysis to validate the new developed pressing tool. / Detta examensarbete handlar om produkt och processutveckling. Arbetet utfördes hos ABB Robotics AB i Västerås och bedrivs under 20 veckor långt på halvfart vilket motsvarar 15 högskolepoäng. Uppdraget är att förbättra en monteringsstation för plockningsrobot IRB360 FlexPicker. Problem på monteringsstation är att det sker icke värdeskapande aktiviteter, och monteringsprocess som leder till arbetsmiljöproblem. Arbetet fokus var att undersöka möjligheter och ta fram konkreta förslag att hur man kan eliminera dessa problem. Efter skriftligt kontrakt med ABB AB, arbetet började med planeringen med företaget handledare och skapades Gantt Schema. Projektet har följt metoderna som beskrivs i boken ”Produktutveckling konstruktion och design” av författare Karl T Ulrich &amp; Steven D Eppinger. I utvecklingsprocessen har använt produktutvecklingsverktyg, några av dessa är QFD, funktionsanalys, kravspecifikation och Pughs analysmatris. I första fas av projekt gjorde undersökning och observation för att hitta och analysera problem. I senare faserna genererade koncepter för åtgärden och sedan vidare utvecklades utvalda koncept för nå framgångsrikt resultat. Resultatet av arbetet blev förbättrad materialflöde som eliminerar icke värdeskapande aktiviteter. Dessutom utvecklades fram ett nytt pressverktyg som eliminerar arbetsmiljöproblem. Mjukvaran Solidworks har använt för att skapa en ny layout för monteringsstation. Med hjälp av Solidworks gjordes FEM -analys (Finita elementmetoden) för att validera den nya pressverktyg