This master thesis is performed at Scania Axles and Gearboxes, a production plant located in Södertälje. Within the plant axles, gearboxes as well as central gears are assembled from components to finished products. All production is conducted on production lines, with a pre-determined rate, which is supplied with components by the material handling department. Since the production quantity and the mix of product variants produced on the production line is customer order-based, the number and type of components needed for production as well as appropriate staffing within the material handling department is difficult to predict. Scania is currently using a number of different resource planning tools for each material handling-department within Axles and Gearboxes to visualize the workload within the departments. These systems however have different structure and are all not sufficiently updated, which means that they cannot fulfill their intended purpose. The aim for this thesis is to develop a common tool for the whole department of Axles and Gearboxes which can visualize the amount workload that prevails. This tool should also be able to account for varying production conditions. The resource planning tool which has been developed within this project is built upon the basis of a structure for occupancy calculation on a position, which includes the premise that a working position contains a number of operations to be performed a certain number of times during a given a number of working hours. The amount workload within a working position is calculated as the ratio how long an operation takes to perform, the number of times the task needs to be performed and during what amount of time it has to be done. The structure of the tool takes into account the following conditions; production quantity, production rate, volume of incoming and outgoing goods and the mix of product variants assembled on the production line. Based on the structure of the occupancy calculation for the material handling department, an additional study has been made to evaluate how the above listed conditions of production affects the occupancy, and to what degree. This study has been conducted using both qualitative and quantitative information obtained from both interviews and historical data extracts. After this data collection, the resource planning tool has been built in Microsoft Excel. The developed resource planning tool enables a visualization of the total amount of workload within a working position in the form of a percentage which shows the proportion of working time used during a shift. That percentage presented in the tool varies thereafter when changing any of the above mentioned production conditions. By the end of the thesis, a number of working positions from the department of Axles and Gearboxes has been imported to the resource planning tool to be able to make appropriate testing and sensitivity analysis of the result. The task that Scania has yet to perform before they can use the tool for the whole department is to continue with the work of importing remaining working positions. The developed resource planning system and the result of this master thesis is a dynamic tool which Scania can use to predict the need of resources in the material handling department for future changes in production conditions, such as time reductions, increased demand for products or changes in work routines.
| Identifer | oai:union.ndltd.org:UPSALLA1/oai:DiVA.org:liu-78522 |
| Date | January 2012 |
| Creators | Axin, Kajsa, Jonzon, Camilla |
| Publisher | Linköpings universitet, Logistik, Linköpings universitet, Tekniska högskolan, Linköpings universitet, Logistik, Linköpings universitet, Tekniska högskolan |
| Source Sets | DiVA Archive at Upsalla University |
| Language | Swedish |
| Detected Language | English |
| Type | Student thesis, info:eu-repo/semantics/bachelorThesis, text |
| Format | application/pdf |
| Rights | info:eu-repo/semantics/openAccess |
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