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Title Balancing of flow groups and implementation of LEAN manufacturing principles
Author Rasmussen, Thomas E.
Institution Technical University of Denmark, DTU, DK-2800 Kgs. Lyngby, Denmark
Thesis level Master's thesis
Year 2004
Abstract 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.
Imprint Institut for Produktion og Ledelse, DTU
Pages 150
Admin Creation date: 2006-06-22    Update date: 2007-02-24    Source: dtu    ID: 177930    Original MXD