<p>This Master of Science thesis was a part of Pharmadule Emtungas project to construct a mobile automated cell for welding of carbon steel pipe (Heating, Ventilation and Sanitation). Pharmadule Emtunga is using a modular building concept for building pharmaceutical factories. The modules contain these pipes. The goal of the thesis was to present concepts for technical solutions regarding welding methods and fixtures for the cell. Conceptual models for the cell were made with aid of CAD software. A concept generation/evaluation resulted in the winning concept; orbital welding using V-stands as fixture method. The main purpose of the fixture is to offer fast and accurate alignment of pipes, with arbitrary lengths and fittings. The fixture was made after a thorough evaluation of data concerning geometries and occurrences of pipes in a typical pharmaceutical factory.</p><p>A number of efficiency problems concerning welding were identified during the project. The thesis presents a four-step process for increased productivity of welding in workshop as well as in the automated cell:</p><p>1. Change payment routines so that Pharmadule Emtunga does not pay for so called “double welds”, welds that never is carried out.</p><p>2. Update lists of time basis used for billing so that they represent actual time needed.</p><p>3. Increase productivity in welding by obtaining an automated welding cell with work and fixturing as proposed in this thesis.</p><p>4. Increase productivity by introducing orbital welding in the cell.</p><p>Additional work with efficiency should be performed in connection with the execution of these four steps:</p><p>• Possibilities of parallel work in the cell should be investigated.</p><p>• Construction personnel need to work by the “Design for Manufacturing” (DFM) principle.</p><p>• Single-module production would contribute to steady flow through the cell.</p><p>• Better drawing data may increase number of welds performed in workshop.</p>

This Master of Science thesis was a part of Pharmadule Emtungas project to construct a mobile automated cell for welding of carbon steel pipe (Heating, Ventilation and Sanitation). Pharmadule Emtunga is using a modular building concept for building pharmaceutical factories. The modules contain these pipes. The goal of the thesis was to present concepts for technical solutions regarding welding methods and fixtures for the cell. Conceptual models for the cell were made with aid of CAD software. A concept generation/evaluation resulted in the winning concept; orbital welding using V-stands as fixture method. The main purpose of the fixture is to offer fast and accurate alignment of pipes, with arbitrary lengths and fittings. The fixture was made after a thorough evaluation of data concerning geometries and occurrences of pipes in a typical pharmaceutical factory. A number of efficiency problems concerning welding were identified during the project. The thesis presents a four-step process for increased productivity of welding in workshop as well as in the automated cell: 1. Change payment routines so that Pharmadule Emtunga does not pay for so called “double welds”, welds that never is carried out. 2. Update lists of time basis used for billing so that they represent actual time needed. 3. Increase productivity in welding by obtaining an automated welding cell with work and fixturing as proposed in this thesis. 4. Increase productivity by introducing orbital welding in the cell. Additional work with efficiency should be performed in connection with the execution of these four steps: • Possibilities of parallel work in the cell should be investigated. • Construction personnel need to work by the “Design for Manufacturing” (DFM) principle. • Single-module production would contribute to steady flow through the cell. • Better drawing data may increase number of welds performed in workshop.

The degree projects purpose is to explore, analyze and explainwhat quality improvements robotic welding can bring to a company’soperations. The study was carried out as a qualitative case studywith an inductive approach. Together with established theoriesfrom TQM and change management, research of manually performed andautomated welding technology, and requirements from ISO standardshas been used to corroborate the requirements and changes that thewelding company are facing. As method for data collectioninterviews, document studies and benchmarking has been conductedin order to analyze the possible quality improvements the companycan achieve by changing parts of their manufacturing system frommanually to automated welding processes. The result of the studyshows that the company is experiencing inefficiency as aconsequence of the workflow in the existing workshop. The companyare at the planning stage of building av new workshop, where thenew workshop together with implementation of automated weldingprocesses can raise new opportunities and simplify the work forthe coworkers which also can reduce safety hazards. The conclusionof the degree project show that the employees who will be affectedby the implementation are aware of, and they have a positiveattitude to the change process as they will get better knowledgeand expertise due to courses required to operate the robot. Thecompany’s management system must be revised in order to adapt tothe new working methods. In relation to the installations that thecompany delivers, the installations may experience improvedwelding quality and the installations lead time will be reduced.The degree project highlights the importance of planning and thatboth the change and implementation process require structure andcontrol. / Examensarbetets syfte är att utforska, analysera och förklara vilka kvalitetsförbättringarrobotsvetsning kan tillföra ett företags verksamhet. Undersökningen utfördes som en kvalitativfallstudie med en induktiv ansats, vilket innebär att utifrån undersökningens datainsamling somligger till grund, har lämpliga teorier och tidigare forskning och arbeten tagits fram. Teoriernagrundar sig på förändringsledning och offensiv kvalitetsutveckling där kärnan vilar påhörnstensmodellen och PAV-modellen, men även teorier kring kvalitetsbristkostnader ochprocesser har varit viktiga för att belysa de möjliga kvalitetsförbättringar som företaget kan uppnåmed implementering av robotsvetsning. Tillsammans med de etablerade teorierna inom offensivkvalitetsutveckling har forskning och kunskaper om både manuell och automatiserad svetstekniksamt krav från olika ISO-standarder tagits fram för att bättre belysa vad som krävs av ettsvetsföretag och vilka förändringar företaget står inför.Datainsamlingen omfattas av intervjuer med vd och medarbetare i företaget för att etablera nulägetoch undersöka vilka förutsättningar och krav de har till implementeringen av robotsvetsning.Intervjuer har även genomförts med näringslivskontoret i kommunen där företaget villvidareutveckla verksamheten. En leverantör av robotsvetsar har också valts ut för intervjuer för attbättre analysera vilka kvalitetsförbättringar som kan uppnås med att gå från manuell tillautomatiserade svetsmetoder. I tillägg till intervjuer har benchmarking genomförts hos ett annatsvetsföretag som använder svetsrobot i produktionen.Resultatet från studien visar att företaget upplever ineffektivitet som orsak av svåra arbetsflöden iden befintliga verkstaden. Företaget kommer inom kort tid att flytta tillverkningen som omfattasav prefabricering av rörinstallationer till en ny, egen verkstad som ger möjligheter för attimplementera ny teknik som kan förenkla arbetsvardagen för medarbetarna som innebär mindresäkerhetsrisker. Slutsatserna i examensarbetet visar att medarbetarna som påverkas avimplementeringen känner till, och är positiva till förändringen vilket förenklar processen. Underförändringsprocessen kommer medarbetarnas kompetens och kunskaper utökas med utbildning.Företagets ledningssystem måste revideras för att anpassas till nya arbetssätt och utifrånerfarenheter från tidigare forskning och arbeten kommer svetskvaliteten att förbättras och ledtidervid prefabricering kommer att reduceras för företaget. Examensarbetet synliggör vikten avnoggrann planering och styrning av förändringsprocessen.