||Balancing of flow groups and implementation of LEAN manufacturing principles
||Rasmussen, Thomas E.
||Technical University of Denmark, DTU, DK-2800 Kgs. Lyngby, Denmark
||The objective of this master thesis is to improve the value added in the Alfa Laval manufacturing unit OM-CF, producing frame and pressure plates to plate heat exchangers. The problem description is defined in a goal-mean tree, which is the central document during the project.
The primary means to reach the goal are as listed below:
X Reduce lead-time
X Improve utilization of existing equipment
X Balance flow groups
X Reduce site emissions
X OEE value of more than 80 % on bottlenecks
A pre-study verified the possibility of mixing the two existing manufacturing lines into one line manufacturing all products. The backbones were an automated painting process, a new drying/hardening technique and a physical connection of the equipment.
It was even though decided to continue producing on two separated manufacturing lines.
Testing of the catalytic IR-drying technique showed ¡§good¡¨ surfaces with a new paint that has not yet been approved at Alfa Laval. The project found it hard to motivate this investment at the moment.
Simulation studies showed that investments in a conveyor and automated painting at small frame line would reduce the staffing with one shift (three operators). Lead-time can also be reduced by up to 72%. Additionally the lead-time has become more stabile regardless of the quantity and type of plates on the line.
Today¡¦s utilization on big frame line is as low as 50 % or less for both equipment and personal. Simulation studies showed potential for reducing the staffing with one shift. This requires a changed approach to the work routines where the focus is on the bottleneck operations and the availability is measured and improved throughout organized continuous improvement programs and an ongoing OEE-analysis to see the effect of the changes.
||Institut for Produktion og Ledelse, DTU
Creation date: 2006-06-22
Update date: 2007-02-24