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FLOW SIMULATION OF AN OUTPUT SHAFT LINE: Capacity analysis and optimization of the overall process efficiency
Umeå University, Faculty of Science and Technology, Department of Mathematics and Mathematical Statistics.
Umeå University, Faculty of Science and Technology, Department of Mathematics and Mathematical Statistics.
2019 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

Scania CV AB is a world leading provider of sustainable transport solutions. This includes trucks and buses, as well as an extensive offering of product-related services. This project takes place at the Södertälje plant and is carried out under the Transmissions Manufacturing department, with the output shaft line as the main focus. Due to a higher scale of product demand, the department aims to extend the line's production capacity to include both additional components and a higher production volume.

The line under investigation consists of eleven serial processes. The project sets out to investigate the line's dynamic, find a theoretical maximum capacity for different product types and derive a reasonable OPE goal. Moreover, the project's final objective refers to how un-utilized capacity can be revealed.

The project's results are delivered in three distinct parts. Firstly, a complex and thorough simulation model is delivered to the department alongside usage instructions. The model in its entirety is found in appendix A3. It is crucial to ensure that the model describes the real system. Therefore, the second result is an extensive model verification and validation. Lastly, results to where un-utilized capacity can be found is presented.

General findings are that, reducing the cycle times to the times stated in the buy-in contract alongside with reducing the length (but not frequency) of shutdowns gives a considerable capacity enhancement. All further optimization endeavours assumes that the line's cycle times have already been reduced to the purchased times. Moreover, it is possible to increase product type one's manufacturing capacity by 11,4%, product type two's capacity by 13,1% and product types three and four's capacity with 7,2%. The capacity enhancements depends on several parameters for the different product types.

Abstract [sv]

Scania CV AB är världsledande leverantörer av hållbara transportlösningar. Dessa involverar lastbilar och bussar, tillsammans med ett stort utbud av produktrelaterade tjänster. Detta projekt har genomförts på Scanias produktionsenhet i Södertälje, närmare bestämt på Transmissionsbearbetningen, med fokus på bearbetningslinan för utgående axel. På grund av högre produktefterfrågan önskar avdelningen att utöka linans kapacitet genom att tillverka fler produktertyper samt öka produktionsvolymen.

Bearbetningslinan som undersöks består av elva stycken seriella processer. Projektet önskar att undersöka linans dynamik, hitta ett teoretiskt maximum för de olika produkttyperna samt presentera ett rimligt OPE mål för dessa. Slutligen önskar projektet att undersöka hur outnyttjad kapacitet kan återfinnas.

Projektets resultat presenteras i tre olika delar. Först överlämnas simuleringsmodellen till avdelningen tillsammans med en grundlig genomgång av uppbyggnad och funktion. Modellen i dess helhet återfinns i appendix A3. Det är avgörande att säkerställa modellen beskriver det verkliga systemet. Därför innehåller den andra delen av resultatet en omfattande verifiering och validering. Slutligen presenteras resultat rörande var outnyttjad kapacitet kan återfinnas.

Projektets övergripande fynd är att en reducering av cykeltiderna till maskinernas inköpta cykeltider tillsammans med en reducering i maskinstoppens längd (inte frekvens) skulle öka linans kapacitet avsevärt. Alla vidare beskrivna optimeringsförsök förutsätter att linans cykeltider redan reducerats till de inköpta tiderna. I och med detta kan kapaciteten för produkttyp ett ökas med totalt 11,4%, produkttyp två med 13,1% och produkttyperna tre och fyra med 7,9%. kapacitetsökningarna beror på flertalet skilda parametrar för de olika produkttyperna.

Place, publisher, year, edition, pages
2019. , p. 60
Keywords [en]
Simulation, Optimization
National Category
Mathematics
Identifiers
URN: urn:nbn:se:umu:diva-160921OAI: oai:DiVA.org:umu-160921DiVA, id: diva2:1330679
External cooperation
Scania CV AB
Educational program
Master of Science in Engineering and Management
Supervisors
Examiners
Available from: 2019-08-12 Created: 2019-06-26 Last updated: 2019-08-12Bibliographically approved

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