Made available in DSpace on 2016-06-02T19:50:18Z (GMT). No. of bitstreams: 1 4736.pdf: 8813283 bytes, checksum: 59903c8bdaa8abbb479d33c6e6fc1dc0 (MD5) Previous issue date: 2012-12-07 / One of the biggest challenges faced by companies is the production flow coordination along the supply chain (SC) in which they operate. Thus, practices have been developed both in academic and business environments that are used in supply chain management (SCM) since the late 1980's that allows such coordination. For manufacturing flow management process within the plant of a single company, the knowledge about usage of ordering systems can be found in current literature. Thus, the purpose of this thesis is to propose the use of the combined practices in SCM and pull ordering systems in SC. However, these ordering systems are seldom used for coordinating operations in SC, thus, can be assumed with a theoretical gap being exploited in terms of coordination mechanism of production flow in CS. The theoretical and empirical approach was used as methodological procedures. In terms of theory a bibliographic review was applied and was built a conceptual model. In terms empirical, was applied the conceptual model in a real case and was analyzed their consistence and result by simulation. A literature review was conducted to ensure the meaning of production flow coordination and SC and a detailed view of activities that theoretically ensures such coordination through the implementation of the Manufacturing Flow Management Process (MFMP). Based on this set of activities, a survey of the practices used in SCM and a conceptual analysis of contribution of with practice to the MFMP was performed. Meanwhile, another theoretical survey about pull ordering systems was performed with report analysis on the literature about the use of SC. Based on the elements that condone the use of each used practice in SCM and each pull ordering systems, a conceptual model of decision making for the combined use of both was designed. This model can help managers on decision making regarding the best practices and systems for each situation of pull systems. In order to validate the model a case study was performed in an automobile SC. The conceptual model was applied in two cases of the relationship with their suppliers and the impact on production flow coordination was analyzed through simulation. Based on the selected analysis variables there was an increase in the level of production flow management in all cases from the combined use of the practices compared to the previous case. To conclude it can be stated that through appropriate choices of combined use of practices used in SCM and pull ordering systems it is possible to achieve greater production flow coordination in SC. / Um dos maiores desafios enfrentados pelas empresas é a coordenação do fluxo de produção (informações e materiais) ao longo da cadeia de suprimentos (CS) em que estão inseridas. Deste modo, tanto no meio acadêmico como no empresarial, a partir do final da década de 1980, têm sido desenvolvidas práticas que são utilizadas na gestão da cadeia de suprimentos (GCS) que, entre outras funções, contribuem para tal coordenação. Para a coordenação do fluxo de produção das operações no interior da planta de uma única empresa, encontra-se na literatura e na prática a utilização de sistemas de coordenação de ordens (SCOs). No entanto, estes SCOs são raramente utilizados na coordenação de operações na CS, podendo assim admitir uma lacuna teórica a ser explorada em termos de mecanismos de coordenação de fluxo de produção na CS. Desta forma, o objetivo desta tese de doutorado é propor a utilização do uso combinado de práticas utilizadas na GCS e SCO com características puxadas para coordenação fluxo de produção no âmbito da CS. Como procedimento metodológico, o método empregado foi do tipo teórico-empírico. Em termos teóricos utilizou-se como delineamento a pesquisa bibliográfica e o desenvolvimento de um modelo conceitual. Quanto aos aspectos empíricos, a partir de dados de um caso real de CS, foi ilustrada a aplicação do modelo conceitual e analisados a consistência e os resultados da proposta por meio de simulação. Para tanto, foi realizada uma revisão bibliográfica sobre o significado de coordenação de fluxo de produção na CS e detalhadas as atividades que teoricamente garantem tal coordenação por meio da implantação do Processo de Gestão de Fluxo de Manufatura. Baseado neste conjunto de atividades foi realizado um levantamento e uma análise conceitual da contribuição para a coordenação do fluxo de produção de práticas utilizadas na GCS. Paralelamente, foi realizado um levantamento teórico de SCOs que atuam com lógica puxada e verificados relatos na literatura sobre o uso na CS. A partir dos elementos que recomendam o uso de cada prática utilizada na GCS e cada SCO, das especificidades dos sistemas de produção puxados e dos critérios do portfólio de gestão de fornecedores, foi elaborado um modelo conceitual de tomada de decisão para o uso combinado de práticas utilizadas na GCS e SCOs. Tal modelo auxilia os gestores para a tomada de decisão quanto às práticas e os sistemas mais adequados para cada situação de sistemas de produção puxados. Com o intuito de ilustrar o uso do modelo, fez-se a aplicação do mesmo em uma montadora de automóveis em sua relação com alguns fornecedores. Aplicou-se o modelo conceitual para cada caso e analisou-se via simulação o impacto na coordenação no fluxo de produção nos mesmos. Baseado nas variáveis de análise selecionadas, em todas as situações verificou-se o aumento no nível de coordenação do fluxo de produção a partir do uso combinado das práticas em relação à situação anterior. A partir do estudo empírico, pode-se presumir que por meio de escolhas adequadas de uso combinado de práticas utilizadas na GCS e SCOs puxados é possível obter maior coordenação de fluxo de produção na CS.

Made available in DSpace on 2016-06-02T19:51:37Z (GMT). No. of bitstreams: 1 2211.pdf: 1140076 bytes, checksum: 469365839d182856ac4aa04c28489a34 (MD5) Previous issue date: 2008-12-16 / Lean manufacturing tools are well known and implemented to eliminate waste and improve materials flow throughout a production process. These lean principles are now studied and applied to product development process (PDP), aligned to the company s needs to develop and launch new products with lower cost and increased speed. Therefore, the objective of the present dissertation is to propose a production preparation procedure, that emphasizes: the significance of the manufacturing team s participation from project inception by sharing its experience, requirements and constraints; the vision of operational value stream delivery as a result of PDP and value creation related to customer and other stakeholders perception. To validate this proposal, a comparative application took place using a previous project from the company that was studied. Procedure comprehensiveness was assessed by questionnaire sent to professionals from other divisions, in addition to the division team. It was concluded that the proposed procedure is: feasible, updated and applicable; capable of contributing to waste, rework and project time reduction and helpful for sharing manufacturing lean concepts knowledge and expertise with other team members and product development stakeholders. / Atualmente, técnicas da manufatura enxuta são conhecidas e implementadas para eliminar desperdício e melhorar o fluxo de materiais ao longo de um processo de produção. Estes mesmos princípios enxutos são agora estudados e aplicados no processo de desenvolvimento de produto (PDP), alinhados à necessidade das empresas de desenvolverem e lançarem novos produtos com custo competitivo e no menor tempo possível. Portanto, o objetivo deste trabalho é propor um método para a produção, que enfatize: a importância da participação da manufatura desde o início do projeto para compartilhar sua experiência, necessidades e restrições; a visão de entrega de todo o fluxo operacional como resultado do PDP e a criação de valor segundo a percepção do cliente e demais interessados no projeto. Para validar a proposta, ela foi aplicada de forma comparativa em um projeto anteriormente realizado na empresa estudada; sua abrangência foi verificada mediante envio de questionário de avaliação do método a profissionais de outras divisões da empresa, além dos envolvidos no projeto avaliado. Como resultado, concluiu-se pela: viabilidade, atualidade e aplicabilidade do método; capacidade em contribuir para redução de desperdícios, de retrabalhos e do tempo de projeto; possibilidade de compartilhar o conhecimento e experiência da manufatura nos conceitos enxutos com os demais integrantes e interessados do projeto de desenvolvimento de produto.

A Indústria 4.0, ou quarta revolução industrial, é o atual cenário industrial que estabelece um novo paradigma para os sistemas de produção. A indústria 4.0 é compreendida como a implementação da fábrica inteligente que opera de forma mais autônoma e com menor intervenção humana, cujo propósito é prover serviços e produtos inteligentes que atendam às necessidades individuais dos consumidores. A Indústria 4.0 está amparada nos sistemas ciber-físicos (CPS) e na Internet das Coisas (IoT). Neste cenário máquinas e produtos se comunicam entre si visando automatizar os processos industriais por meio de informações individuais obtidas em tempo real durante os processos de manufatura. No entanto, a Indústria 4.0 e as pesquisas em torno desse assunto ainda são muito recentes e requerem mais investigações no que diz respeito às arquiteturas que suportem a sua implementação, entre elas a comunicação entre produtos e máquinas. Neste quesito, recentemente foi proposto o modelo de arquitetura de referência para a Indústria 4.0 (RAMI 4.0) com o objetivo de nortear a implementação deste tipo de sistema. Contudo, o RAMI 4.0 ainda requer esforços no campo da pesquisa sob diferentes aspectos, entre eles a integração vertical de recursos do sistema de produção. Neste sentido, este trabalho objetiva apresentar uma arquitetura para a descoberta de equipamentos para processar operações conforme as necessidades dos produtos. A arquitetura foi projetada em camadas baseadas no RAMI 4.0 para prover componentes que permitam a comunicação entre equipamentos e produtos, e um mecanismo similar ao sistema de nomes de domínios (DNS - Domain Name System) para realizar a descoberta de equipamentos para processar uma determinada operação. Nessa arquitetura as informações dos equipamentos são armazenadas em uma estrutura organizada hierarquicamente para auxiliar o serviço de descoberta, e os produtos possuem informações das operações necessárias para o processo de manufatura. Para garantir a eficácia do funcionamento dos componentes e suas interações, é necessário a verificação e validação por meio de métodos formais. Neste trabalho a verificação e validação é realizada por meio da técnica PFS (Production Flow Schema)/RdP (Rede de Petri). Por fim, a arquitetura é aplicada em um sistema de produção modular para demonstrar a sistemática de implementação e a sua efetividade. / The Industry 4.0, also known as fourth industrial revolution, is the current industrial scenario that sets a new paradigm for production systems. The Industry 4.0 can be understood as the implementation of the smart factory that operates more autonomously and with less human intervention. The purposes of it is to provide smart products and services that meet the consumer individual needs. The Industry 4.0 is supported by cyber-physical systems (CPS) and Internet of Things (IoT). In this scenario machines and products communicate with each other to automate industrial processes through individual information that are obtained in real time during manufacturing processes. However, the researches around this issue are still very recent and require further investigations with regard of to the architectures that support its implementation, including communication between products and equipment. Taking into account this problem, a Reference Architectural Model for Industry 4.0 (RAMI 4.0) was recently proposed with the purpose to guide the implementation of this system type. However, the RAMI 4.0 still requires efforts in different aspects, including the vertical integration of resources of the production systems. In this sense, this work aims to present an architecture for the discovery of equipment to process operations according to the product needs. The architecture was designed based on layers of the RAMI 4.0 to provide components that allow communication between equipment and products and a Web Service that offer a mechanism similar to the Domain Name System (DNS) to locate equipment to process a required operation. In this architecture the capable operations supported by the equipment are stored in a structure organized hierarchically to aid the discovery service, and the products have information of the operation required for the manufacturing process. In order to guarantee the effectiveness of the component functionalities and their interactions it is necessary to verify and validate them by formal methods. In this work the Production Flow Schema (PFS)/Petri Net (PN) technique is used to develop the conceptual and functional modeling of the architecture. Finally the architecture is applied in a modular production system to demonstrate its implementation systematics and its effectiveness.

This is a master thesis in Industrial design engineering at Luleå University of Technology. The project was carried out between August 2017 and January 2018. The thesis is done at Lindbäcks Bygg AB in Piteå. Lindbäcks is a manufacturer of wooden apartment buildings. The buildings are built with modules that are made in factories. In connection to the main factory in Öjebyn,there is an external production line that creates special products. This external production line is referred to the Sub-Factory in this thesis. The objective of the project is to design the Sub-Factory to meet the future needs. By investigating and analyzing the current state as well as the requirements of needs, concepts of change will be developed and presented. The project aim is to present a decision basis onhow to utilize the Sub-Factory in the future and suggestions on implementation of changes to reach the future state. A theoretical framework was established to create a scientific foundation for theproject. To create an understanding of the current state observations, interviews, and document reviewing were the main methods. The main problems were noted. The problems were analyzed to map out their underlying causes. With these problems and causes in mind, objectives of the solution were established. Conceptual solutions were then generated using creative methods such as brainstorming, layout ideation, benchmarking, and workshop. The gathering of data showed that the main problems of the Sub-Factory were that the capacity was limited, and the factory was inflexible. The underlying causes ofthese problems were: wrong or non-arriving material, faulty drawings, waiting,blocked transport aisles, and that the Sub-Factory is less prioritized than otherparts of Lindbäcks. The final results aim to fulfill the objectives of the solutions. The final solution consists of five concepts; layout, routines, machines and equipment, test runs, and production planning. The layout solution aims to solve several of the objectives by inducing shorter and more efficient flows. The other concepts aim to complement the layout so that all objectives can be fulfilled. To implement these solutions an implementation strategy has been established. The implementation strategy suggests an order of implementation and why to implement in this particular order.

The purpose of the master thesis has been to examine the production system at the company Lundqvist Trävaru AB and use the gathered information to create a layout suggestion together with a couple of improvement ideas. The thesis is the final part of the Industrial Design Engineering programme at Luleå University of Technology (LTU). Lundqvist Trävaru AB is a manufacturing company that specializes in producing prefabricated building kits out of wood, but the insufficient size of their current factory located in the industrial area of Öjebyn on the outskirts of Piteå, have created a need to relocate to alarger site. This new site is located at Haraholmen south of Piteå. The aim and objective have therefore been to develop a layout suggestion as well as a couple of improvement ideas, with the purpose of solving the identified problems at the current factory, thereby making sure that they do not reappear at the new site. Methods in the form of interviews, observations and documentation reviews were performed to identify potential problems with the production system and the work organization. To aid the investigation of the current factory, literature reviews of scientific books and articles were also performed during the project, with the purpose of giving the thesis a solid scientific foundation. After an overview of the production system had been created, the next step was to analyze the identified problems. These affected many different aspects of the company, for instance the material handling, work organization, flow ofinformation, production flexibility, inventory capacity and production flow. The main problem that in turn caused many of the identified problems was the insufficient inventory capacity, which led to problems with overflowing inventories and long delivery times for materials. This in turn affected thematerial handling negatively and made it hard to keep track of materials in the factory.  Additional problems that were identified was divided workstations, scattered areas for material storage, an increasing amount of special orders with dimension outside of the ordinary size range, a lack of standardized working methods and lack of communication between the office and the production team. After the problems had been identified, the next part of the project was dedicated to performing creative methods with the purpose of developing layout concepts as well as improvement ideas. The methods that were used to fulfill this task was brainstorming, mind map, requirement specification, proximity chart and workshop. After these methods had been performed the result was four layout concepts and several improvement ideas.  The next step was to evaluate the layouts and the ideas with the help of the requirements that had been specified together with the management at Lundqvist. The evaluations resulted in a final layout together with the most promising improvement ideas. These ideas were to standardized drawings and working methods, increase the work with creating manuals for the different stations and machines, adapt the workstations for special orders, purchase tablet computers for each workstation thereby allowing better information sharing and contact between the production team and the office, create a digital map of the factory, use markings and colors at inventories to facilitate identification of specific materials, better routines for the disposal of production waste and larger passages for trucks and wheel loaders. The result of the last part of the project was a 3D-model of the factory and the site, which showed the placement of the different machines, workstations and inventories used during the production of the prefabricated building kits. The benefits of the suggested layout and improvement ideas are bettermaterial handling, increased inventory capacity, better information sharing, standardized working methods and drawings, a straighter production flow and an increased production flexibility, which gives a better ability to produce special orders. If it turns out that it is hard to implement the layout at thepresent, the recommendation for Lundqvist Trävaru AB is to start with implementing the improvement ideas and then successively implement the layout. The suggested ideas and layout will make the company more prepared for the future and increase their ability to handle the planned productionincrease, while also making sure that they are able to better keep production deadlines, attract more customers and successfully establish themselves at Haraholmen. Which in turn will lead to reduced unemployment and increased tax revenue for Piteå municipality / Syftet med examensarbete har varit att undersöka produktionssystemet hos företaget Lundqvist Trävaru AB, samt använda den insamlade informationen för att skapa ett layoutförslag tillsammans med ett par förbättringsidéer. Detta examensarbete är sista delen av programmet Teknisk Design vid Luleå Tekniska Universitet (LTU). Lundqvist Trävaru AB är ett tillverkningsföretag som är specialiserade på att producera prefabricerade byggsatser gjorda av trä, men otillräckligt utrymme vid deras nuvarandefabriken belagd i industriområdet Öjebyn i utkanten av Piteå, har skapat ett behov av att flytta till en större anläggning. Denna nya anläggning är placerad i Haraholmen söder om Piteå. Syftet och målet har därför varit att utveckla ett layoutförslag, såväl som ett antal förbättringsförslag, med syftet att lösa de identifierade problemen vid den nuvarande fabriken och därmed se till att de inte dyker upp igen vid den nya anläggningen. Metoder i form av intervjuer, observationer och dokumentgranskningar utfördes för att identifiera potentiella problem med produktionssystemet och arbetsorganisationen. För att underlätta undersökningen av den nuvarande fabriken utfördes också litteraturgranskningar av vetenskapliga böcker och artiklar under projektets gång, i syfte att ge examensarbetet en stabil vetenskaplig grund. Efter att en översikt av produktionssystemet hade skapats var nästa steg att analysera de identifierade problemen, vilket påverkade många olika aspekter av företaget, bland annat materialhanteringen, arbetsorganisationen, informationsflödet, produktionsflexibiliteten, lagerkapaciteten och produktionsflödet. Huvudproblemet som i sin tur orsakade många av de identifierade problemen, var den otillräckliga lagerkapaciteten, som lede till problem med överfyllda lager och långa leveranstider för material. Detta påverkade i sin tur materialhanteringen negativt och gjorde det svårt att hålla reda på material i fabriken. Ytterligare problem som identifierades var uppdelade arbetsstationer, utspridda områden för materiallagring, en ökande mängd specialbeställningar med dimensioner utanför det vanliga storleksområdet, brist på standardiserade arbetsmetoder samt brist på kommunikation mellan kontoret och produktionsteamet. Efter att problemen hade identifierats ägnades nästa del av projektet åt att utföra kreativa metoder i syfte att utveckla layoutkoncept och förbättringsidéer. Metoderna som användes föratt utföra denna uppgift var brainstorming, mind map, kravspecifikation, närhetsanalys och workshop. Efter att dessa metoder hade utförts blev resultatet fyra layoutkoncept och flera förbättringsidéer. Nästa steg var att utvärdera layouterna och idéerna med hjälp av de krav som hade specificerats tillsammans med ledningen hos Lundqvist. Utvärderingen resulterade i en slutlig layout tillsammans med de mest lovande förbättringsidéerna. Dessa idéer var att standardisera ritningar och arbetsmetoder, öka arbetet med att skapa manualer för de olika stationerna och maskinerna, anpassa arbetsstationerna för specialbeställningar, köpa surfplattor för varje arbetsstation och därmed möjliggör bättre informationsdelning och kontakt mellan produktionsteamet och kontoret, skapa en digital karta över fabriken, använda markeringar och färger vid lager för att underlätta identifiering av specifikt material, bättre rutiner för hantering av produktionsavfall och större passager för truckar och traktorer. Resultatet av projektets sista del var en 3D-modell av fabriken och tomten, som visade placeringen av de olika maskinerna, arbetsstationerna och lagren som används under produktionen av de prefabricerade byggsatserna. Fördelarna med den förslagna layouten och förbättringsidéerna är bättre materialhantering, ökad lagerkapacitet, bättre informationsdelning, standardiserade arbetsmetoder och ritningar, ett rakare produktionsflöde samt ökad produktionsflexibilitet, vilket ger en bättre förmåga att producera specialbeställningar. Om det visar sig vara svårt att implementera layouten i nuläget är rekommendationen för Lundqvist Trävaru AB att börja med att implementera förbättringsidéerna och sedan succesivt implementera layouten. De förslagna idéerna samt layouten kommer att göra företaget mer förberett för framtiden och öka deras förmåga att hantera den planerade produktionsökningen, samtidigt som de ser till att de kan hålla produktionsdeadlines bättre, locka fler kunder och framgångsrikt etablera sig på Haraholmen. Vilket i sin tur kommer att leda till minskad arbetslöshet och ökade skatteintäkter för Piteå kommun.

Für die Reinigungseffizienz ist die Kenntnis des Wirkzusammenhangs zwischen Schmutzbeschaffenheit und Reinigungsverhalten bedeutsam, da der Reinigungsbedarf von den Schmutzeigenschaften bestimmt wird. Bisher ist jedoch unzureichend dokumentiert, worauf der Reinigungsbedarf von kohäsiven Lebensmittelrückständen im immergierten System zurückgeführt werden kann. Anhand von Reinigungsuntersuchungen in einer Fließzelle werden die Auswirkungen physikochemischer Schmutzparameter (z.B. elektrisches Potential, energetischer Zustand, Molekülgröße) von Proteinen und Stärken getestet, um Empfehlungen für eine ressourceneffiziente Reinigungspraxis abzuleiten. Die Vielfalt der physikochemischen Eigenschaften von Lebensmittelinhaltsstoffen wird durch gezielte Modifizierung (physikalisch, chemisch, enzymatisch) simuliert und unter Anwendung verschiedener Analysetechniken charakterisiert. Die vorgestellte Durchflusszelle ermöglicht vergleichende Untersuchungen zum Abtragsverhalten an einer Vielzahl von Verschmutzungen in verschiedenen Messkonfigurationen. Es konnten Prozessbedingungen (Fließrate, Temperatur) identifiziert werden und die Genauigkeit der Fließmethode durch Vergleich von spektroskopisch und gravimetrisch ermittelten Abtragswerten gezeigt werden. Die Reinigungsuntersuchungen an Polymerverschmutzungen zeigten eine deutliche Differenzierung hinsichtlich Polymerart und pH der Modifizierung und können auf Lifschitz van der Waals- oder elektrostatische Wechselwirkungen zurückgeführt werden. Die Auswirkungen hitzeinduzierter Strukturveränderungen und der Proteinvernetzung waren nicht signifikant. Der Grad der enzymatischen Stärkehydrolyse wurde über rheologische Messungen und den DE-Wert charakterisiert, wobei mit zunehmender Inkubationsdauer die Reinigungseffizienz in ähnlicher Weise zur Löslichkeit steigt. Die Anwendung eines Enzymreinigers aus Diastase verbesserte signifikant die Reinigungseffizienz von Stärke- sowie Dextrinverschmutzungen und es wurde eine Modellvorstellung abgeleitet, nach der geringer kationisch geladene, niederenergetische und niedermolekulare Rückstände einen kleineren Reinigungsbedarf erfordern.

Abstrakt Examensarbete. Civilekonomprogrammet, Logistik, Linnéuniversitetet, 4FE05E, Våren 2011. Författare: Alexander Avander och Erik Robertsson Handledare: Peter Berling   Titel: Batch size policy Thule Vehicle Solutions - A case study in Hillerstorp   Bakgrund: Företaget har för närvarande ingen tydlig batch policy och detta är ett område som uppmärksammats som ett område med potentiella förbättringsmöjligheter. Ett projekt har inletts där två flöden (en hög omsättare och en låg) skall kartläggas och generera ett förslag till en tvärfunktionell batch policy.   Syfte: Syftet med projektet är att med hjälp utav en ”current state map” föreslå en ny, kostnadseffektiv och tvärfunktionell batch policy samt jämföra detta med nuvarande policy för att påvisa potentiella förbättringsmöjligheter.     Metod: Projektet använder ett kvalitativt arbetssätt för att påvisa effekter utav batch storlekar. Data hämtas från det undersökta företaget och från tidigare forskningar inom området som samlats genom universitetets resurser.   Slutsatser: Företaget bör kunna eliminera ett flertal lager i sitt flöde som uppstått på grund av en batch policy där hela pallar föredras. En batch policy, där en storlek används till ett komponentlager och därefter en annan storlek som är en jämn del utav den första till slutlagret, har föreslagits som en tvärfunktionell batch policy. Detta förslag är testat i fyra versioner där samtliga var funna mer kostnadseffektiva än nuvarande policy. Att använda mindre batchstorlekar i den föreslagna policyn sänkte lagernivåer och ledtider. Dock var nuvarande, större batchstorleken mer optimal då lagerhållningskostnaderna är låga i förhållande till omställningskostnader.   Sökord: Batch size, batch size costs, cross functional, inventory control, lean management, production flow, supply chain integration, transportation costs, value stream mapping. / Abstract   Master Degree Project. Business Administration and Economics Programme, Linnaeus University, Logistics, 4FE05E, Spring 2011. Authors: Alexander Avander and Erik Robertsson Supervisor: Peter Berling   Title: Batch size policy Thule Vehicle Solutions - A case study in Hillerstorp   Background: The Company has currently no clear batch size policy and batch sizes are an area that has been recognized with potential earnings within the company. A project to map two flows (a high volume and a low volume) and suggest a new cross functional batch size policy has been initiated.   Purpose: The purpose of this project is to, with the help of a current state map, propose a new cost effective and cross functional batch size policy for the business unit car accessories and compare this to the present batch size policy to show possible earnings.     Method: This project uses a qualitative approach to show the effect of batch sizes with data supplied from the Thule Sweden AB and researched through the Linnaeus University’s recourses.    Findings: Thule Vehicle Solutions should be able to remove several inventories that have been caused by a batch size policy where whole pallets are preferred. A batch size policy where one batch size is used to the semi-finished inventory and another size, part of first batch size, from that inventory until the finished-goods inventory has been suggested as a cross functional batch size policy. This suggestion has been tested and in four different versions was found more cost effective than the current policy. Using smaller batch sizes in the suggested batch size policy decreased inventory levels and lead times. However, the current, larger batch size was more optimal as the holding costs are low and the set up costs are high.   Key words: Batch size, batch size costs, cross functional, inventory control, lean management, production flow, supply chain integration, transportation costs, value stream mapping.

Höga byggkostnader och betydande bostadsbrist i Sverige visar att ett effektivare bostadsbyggande krävs. En reducering av slöseri i byggprocessen bidrar till en effektivisering av både tid och kostnad. För att öka förståelsen för vikten av effektivisering synliggör den här studien slöseri i produktionsflödet för en platsgjuten betongvägg i ett bostadsprojekt. Studien visar även var i produktionsflödet det finns förbättringsmöjligheter. Slöseriet synliggjordes genom en tidsstudie som visade på stor potential till förbättring i bostadsprojektets resursflöde, materialflöde och informationsflöde. Mycket tyder på att dessa brister i produktionsflödet beror på allt för kort byggtid, vilket leder till att en fullgod planering inte alltid utförs. / High construction costs and considerable housing shortages in Sweden show that a more efficient housing construction is required. A reduction of waste in the construction process contributes to the efficiency of both time and cost. In order to increase the understanding of the importance of efficiency, this study reveals waste in the production flow of a cast in-situ concrete wall in a housing project. The study also shows where in the production flow there are improvement opportunities. The waste was made visible through a time study which showed great potential for improvement in the housing project resource flow, material flow and information flow. There are many indications that these shortcomings in the production flow are due to a too short construction time, which means that a good planning is not always carried out.

Denna studies syfte är att leverera ett förslag på hur ett tillverkande företag i Sverige kan öka sin kapacitet, sitt genomflöde och flexibilitet i en manuell produktionslina. Produktionsgolvet är trångt för de anställda på grund av stora lagernivåer intill produktionslinan. Det finns fem arbetsstationer, tre flaskhalsar i produktionen och antalet PIA (Produkter I Arbete) är högt. Studien genomför mätningar för att kartlägga nuläget, hur den aktuella layouten och prestandan ser ut. För att mäta nuläget samlar studien in data genom observationer, en processpromenad, informella intervjuer och genomför egna mätningar. Datainsamlingen analyseras med hjälp av teorier och metoder från Lean, TOC (Theory of Constrains), linjebalansering och produktionsledning. Studien använder sig av 5s som angreppssätt för att systematiskt uppnå genomgående renhet av arbetsplatsen och en standardisering av påfyllnads- och prognostiseringsprocessen. Studien finner att för att öka produktionslinans kapacitet kan bemanningen på produktionslinan ökas, med detta som utgångspungspunkt föreslås en ny layout som tillåter två extra anställda att arbeta på produktionslinan. Detta uppnås genom att dela upp nuvarande delmoment i produktionslinan och skapa två extra stationer. Detta ändrar antalet arbetsstationer från fem till sju och tillåter två extra anställda att arbeta i produktionslinan. Detta eliminerar också två mindre flaskhalsar i produktions flödet. Vidare innefattar förslaget en ny rutin för påfyllnad- och prognostiseringsprocessen som bestämmer hur många artiklar som ska lagerföras vid produktionslinan. Till sist föreslås att den nu enda flaskhalsen ska styra takten, vilket gör processen till ett dragande system styrt av efterfråga istället för ett styrt av generell tillgång. Detta innefattar också att produktionslinan ska börja tillverka ett säkerhetslager med färdiga produkter, detta säkerhetslager ska bytas ut kontinuerligt för att hindra produkterna passerar utgångsdatum. Resterande majoritet av produktionen ska endast ske mot kundorder istället för mot ett lager. För att implementera förslaget bör organisationen utbilda sig och dess anställda i teorierna studien använder sig av. Både ledning och anställda i produktionslinan måste förstå teorierna och varför de används för att implementeringen ska lyckas. / The purpose of this study is to deliver a proposition on how a Swedish manufacturing company can improve its’ capacity, flow and flexibility in a manual production line. The production floor is crowded as a result of large quantities of articles adjacent to the production line. The production line has five workstations, three bottlenecks and has a high number of WIP (Work-In-Progress). The study collects data to assess the situation, the production lines performance and how the current layout is planned. To measure the current situation the study collects data through observations, a process tour, informal interviews and conducts its own measurements. The collected data is analysed using theories and methods from lean, TOC (Theory of Constrains), line balancing and production management. The study is approaching the problems using 5s to systematically achieve pervading cleanness in the workplace and a standardisation of the refilling- and prognostication process. The study finds that to increase the capacity of the production line, the staffing can be increased. Using this as a standing point, the study proposes a new production layout that allows two extra employees to work on the production line. This is achieved by creating two additional workstations in the production line. Changing the number of stations from five to seven and allowing two extra employees to work in the production line. This layout change also eliminates two smaller bottlenecks in the production flow. Furthermore, the propositions suggest a new routine for the refilling- and prognostication process that determines how many articles to store within the production floor. Lastly the proposition suggests that the now single bottleneck in the production flow decides the production rate. Making the production line a pulling system set by the demand of the bottleneck, rather than a system set by general assets. This also includes that the production line is going to start producing safety stock of completed products, this safety stock will continuously be replaced to prevent the products from passing expiration date. The remaining majority of the production should only be done by customer order, rather than producing to store complete products. In order to implement the proposition, the organization need to educate itself and its employees, both management and workers need to understand the concepts the proposition uses and why the concepts are used in order for the implementation to be successful. / <p>Sekretess</p>

Då tillverkningsindustrin går mot en högre grad av kundanpassning och implementering av Lean, samtidigt som föråldrade traditionella kalkyleringsmetoder fortfarande används i moderna industriföretag, är det intressant att utreda relationerna mellan produktionsflöden av kundanpassad karaktär, Lean samt olika kalkyleringsmetoder. Syftet är att öka kostnadsprecisionen i förkalkylen för ett produktionsflöde av kundanpassad och Lean karaktär och beskriva en generaliserbar arbetsprocess för detta. Syftet är även att ta fram generella rekommendationer för val av kalkyleringsmetod genom att utifrån denna produktions karaktär genomföra en jämförande analys av kalkyleringsmetoder (traditionella kalkylmetoder, ABC och kalkylering enligt Lean). Genom en litteraturstudie samt en fallstudie av ett produktionsflöde med många varianter och inslag av Lean har båda syftena uppfyllts. Fallstudien har utförts genom intervjuer och observationer. Problem och positiva faktorer som enligt litteratur karaktäriserar produktion av kundanpassade produkter har även återfunnits på fallföretaget. Det sambandet har kunnat användas för att stödja analysen av relationerna. Relationerna mellan kalkyleringsmetoder, Lean samt produktionsflöden av kundanpassad karaktär har analyserats genom att jämföra litteratur och resultat från fallstudien. Det framkom att Value Stream Costing (VSC) är den mest lämpliga kalkyleringsmetoden för produktionsflöden med kundanpassade produkter som uppnått en hög mognadsgrad av Lean. Förkalkyleringen på fallföretaget är beroende av tillförlitliga operationstider, vilket tagits fram på fallföretaget samtidigt som en generell arbetsprocess utarbetats. Operationstiderna togs i detta fall fram genom videoupptagning av produktionsmomenten samt efterföljande analys i mjukvaran AviX. Genom att följa den generella arbetsprocessen som utarbetats erhålls både ett bra underlag till förkalkylering samt ständiga förbättringar i produktionsflödet. Eftersom forskning visar att Lean bör implementeras i hela organisationen om full fördel med Lean ska uppnås, kan VSC vara en utmärkt kalkyleringsmetod för att komma ifrån föråldrade, traditionella kalkyleringsmetoder samtidigt som denna kalkyleringsmetod förenklar kalkylering i produktion av kundanpassad karaktär. / Since the manufacturing industry is heading for a higher level of customization and implementation of Lean, at the same time as outmoded traditional costing methods is still used in modern industrial organizations, it is interesting to explore the relations between production flows of customized character, Lean and different costing methods. The purpose of this thesis is to increase the cost precision in the preliminary calculation for a product flow of customer adapted and Lean character, and to describe a generalizable work process for this. The purpose is also to develop general recommendations regarding the choice of costing methods by, on a basis of the character of this production, a comparative analysis of costing methods (traditional costing methods, ABC and Lean accounting/VSC). Through a literature study and a case study of a production flow with a high level of variety and influence from Lean, both of the purposes has been fulfilled. The case study has been accomplished through interviews and observations. Problems and positive elements that according to literature characterize the production of customized products have also been found in the case company. That connection has been used to support the analysis of the relations. The relations between costing methods, Lean and production flows of customized character has been analyzed through a comparison between findings in literature and results from the case study. It has been found that Value Stream Costing (VSC) is the most appropriate costing method for production flows of customized products that has reached a high maturity level of Lean. The preliminary costing is dependent on reliable operation times which have been produced on the case study company, while a general work process has been developed. The operation times were in this case identified through video recordings of the production moments and a following analysis in the software AviX. By following the general work process that has been developed, useful material for preliminary costing and continuous improvements in the production flow will be obtained. Since research is showing that Lean should be implemented in the whole organization if full advantages of Lean shall be obtained, VSC is found to be an ideal costing method to replace outmoded, traditional costing methods at the same time as this costing method simplifies costing in production flows of customized character.