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A Capacity Flexible Assembly Line - with the least possible amount of wastes

Lindmark, M (2008)
Production and Materials Engineering
Abstract
Purpose: The purpose of this master thesis is to design a capacity flexible
assembly line with as few wastes as possible in the internal material supply
chain. The reports secondary purpose is to show the advantages of involving
logistics in the design phase of an assembly line.
Method: The study starts of with an explanative approach as assembly line six
is investigated and wastes are identified. During the design phase of the study a
normative approach is used since a solution is found for the identified problems
and wastes. The strategy is inductive and the study is carried out qualitatively.
Interviews and observations are used as primary data and student literature is
used as secondary data. The report has a high validity and... (More)
Purpose: The purpose of this master thesis is to design a capacity flexible
assembly line with as few wastes as possible in the internal material supply
chain. The reports secondary purpose is to show the advantages of involving
logistics in the design phase of an assembly line.
Method: The study starts of with an explanative approach as assembly line six
is investigated and wastes are identified. During the design phase of the study a
normative approach is used since a solution is found for the identified problems
and wastes. The strategy is inductive and the study is carried out qualitatively.
Interviews and observations are used as primary data and student literature is
used as secondary data. The report has a high validity and objectivity, the
reliability is seen to be imponderable.
Theory: The theory chapter presents a theoretical frame of references. The lean
production part- chapter describes two tools in the lean philosophy; seven
wastes and kanban. The reader is also presented to a short introduction about
how to group working moments into stations in a production line, which
measures of flexibility there are, optimal automation level and how to calculate
balance loss.
Empirical foundation and analysis: The empirics consists of a detailed
description of the factory, assembly line six and how the internal material
supply chain works at present time. The next chapter analysis the empirics
which results in identified wastes, defects and question marks. Identified wastes
are found in five of lean production's "seven wastes". The most important
defect found is the lack of capacity flexibility.
Design of the assembly line: How the author decides to build the assembly line
and why a U- layout is found most appropriate, is described in the design
chapter. An effective internal material supply chain is also designed in this
________________________________________________________________
IV
chapter as well as the calculations for how the amount of material suppliers
vary with the cycle time.
Result and discussion: The result of this master thesis is an assembly line that
is able to assembly Haldex Traction's generation four coupling with a cycle
time that varies from 50 to 155 seconds. In the interval there are six optimized
cycle times that have a balance loss of 14 % or less. The internal material
supply chain has a reduced amount of wastes due to elimination of e.g.
unnecessary stock and working moments. (Less)
Please use this url to cite or link to this publication:
author
Lindmark, M
supervisor
organization
year
type
H2 - Master's Degree (Two Years)
subject
ISSN
CODEN:LUTMDN(TMMV-5225)1-64/2008
language
Swedish
id
1513528
date added to LUP
2010-11-03 14:29:48
date last changed
2012-09-10 14:57:49
@misc{1513528,
  abstract     = {Purpose: The purpose of this master thesis is to design a capacity flexible
assembly line with as few wastes as possible in the internal material supply
chain. The reports secondary purpose is to show the advantages of involving
logistics in the design phase of an assembly line.
Method: The study starts of with an explanative approach as assembly line six
is investigated and wastes are identified. During the design phase of the study a
normative approach is used since a solution is found for the identified problems
and wastes. The strategy is inductive and the study is carried out qualitatively.
Interviews and observations are used as primary data and student literature is
used as secondary data. The report has a high validity and objectivity, the
reliability is seen to be imponderable.
Theory: The theory chapter presents a theoretical frame of references. The lean
production part- chapter describes two tools in the lean philosophy; seven
wastes and kanban. The reader is also presented to a short introduction about
how to group working moments into stations in a production line, which
measures of flexibility there are, optimal automation level and how to calculate
balance loss.
Empirical foundation and analysis: The empirics consists of a detailed
description of the factory, assembly line six and how the internal material
supply chain works at present time. The next chapter analysis the empirics
which results in identified wastes, defects and question marks. Identified wastes
are found in five of lean production's "seven wastes". The most important
defect found is the lack of capacity flexibility.
Design of the assembly line: How the author decides to build the assembly line
and why a U- layout is found most appropriate, is described in the design
chapter. An effective internal material supply chain is also designed in this
________________________________________________________________
IV
chapter as well as the calculations for how the amount of material suppliers
vary with the cycle time.
Result and discussion: The result of this master thesis is an assembly line that
is able to assembly Haldex Traction's generation four coupling with a cycle
time that varies from 50 to 155 seconds. In the interval there are six optimized
cycle times that have a balance loss of 14 % or less. The internal material
supply chain has a reduced amount of wastes due to elimination of e.g.
unnecessary stock and working moments.},
  author       = {Lindmark, M},
  issn         = {CODEN:LUTMDN(TMMV-5225)1-64/2008},
  language     = {swe},
  note         = {Student Paper},
  title        = {A Capacity Flexible Assembly Line - with the least possible amount of wastes},
  year         = {2008},
}