Production Line Performance : An Assessment in the Context of Preliminary Technology Integration

Abstract (Swedish)

This study was conducted in collaboration with Air Liquide France Industry and investigates one of the production lines of the company.The quality of gas cylinders must be assessed every 10 to 15 years for safety reasons. The line studied in this study evaluates the quality of cylinders by both a visual inspection and a hydraulic pressure test. As awareness of the environmental impact of such large water quantities is rising, a different technology has been chosen to assess the cylinders quality. This ultrasonic bench test allows for in depth non-invasive inspection, but its integration on the existing production line has consequences.
This study aims to give a fresh perspective on the existing line, to assess its performance through data analysis including both quantitative data and qualitative data. Cycle times, downtimes, bottle neck identification, buffer stock analysis as well as key performance indicators such as Line Efficiency and Technical Efficiency were studied as quantitative data. The organizational structure of the company as well as knowledge management and obsolescence risk management are also discussed.
The results demonstrated several discrepancies between theoretical design and actual performance. Imbalances between the workstations and significant bottlenecks are observed, causing numerous short-duration downtime across the line which are not addressed as large buffer stocks and informal adaptations are masking them, in an effort to achieve the best possible performance despite the difficulties encountered. The calculations showed that the line has a fair Line Efficiency, indicating structural imbalances but a low Technical Efficiency suggesting an important underperformance relative to its maximum potential. Observations showed deficiencies in project management, knowledge management and risk assessment, in a context of friction between traditional and modern organizational mentalities.
The overall conclusion is that even though the integration project is progressing, operational and organizational challenges are currently hindering the line performance. To aim for amelioration and continuous improvement, robust communication, maintenance monitoring and proactive attention to human factors need to be consolidated.

Popular Abstract

Factory Detectives: Uncovering Hidden Performance Secrets

Imagine a factory line, running with tireless precision, a relentless ballet between machines and human. But what if a closer look reveals that efficiency isn't just about what meets the eye? Embark with me on a detailed exploration inside a gas cylinder plant, seeking to understand its true operational dynamics.

To begin our investigation, let’s talk about the product : gas cylinders. As you may know, gas leak or gas cylinder explosion is … a little bit problematic, right ? Yeah, we want to avoid that, that’s why the quality of the cylinders must be verified every 10 to 15 years with rigorous criteria. This is exactly what our production line does : feed it with a cylinder, and it will be checked, high-pressure tested, and if there are no problems, it will be painted anew and fitted with brand new accessories (like a new valve) before going back to circulation. Great, isn’t it ? Let’s dig in a bit deeper. This line has been operating for more than 10 years. That is quite impressive to see that it is almost the same as in the beginning. But you may have heard that technology is moving fast, no ? Such a line, still operating without major alterations, could it be a revolutionary line ? It seems there might be something to uncover here…

For my analysis I spent a lot of time observing the line to understand it. I also talked with the operators and other involved people. I gathered data : the time the cylinders spend at each workstation, the downtimes, among others. As I pieced together the clues, one finding became clear : the smooth operation is but hiding some issues. Firstly, the time spent at each workstation : to have a good flow, we want the cylinder to spend approximately the same time at each workstation. This balance is upset in our case. Secondly, the downtimes are extremely recurrent, be it little stops due to waiting the next cylinder or problems with one of the machines that needs to be restarted or repaired. Of course, these two points do not prevent the line from operating, but it is exactly the problem : as it is currently operating despite the problems, resolving them is not a priority. And it seems this has been the case for the last 10 years : every new problem found a temporary solution, just enough to invisibilize it. So, what is the next step in this industrial mystery ? The evidence suggests that improved communication and monitoring are key instruments to unlock the line full potential.

• author: Duran, Léonie
• supervisor: Christina Windmark
• organization: Production and Materials Engineering
• course: MMTM05 20251
• year: 2025
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• report number: LUTMDN/(TMMV-5383)/1-56/2025
• language: English
• id: 9204280
• date added to LUP: 2025-06-23 09:50:01
• date last changed: 2025-06-23 09:50:01