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Optimization of Batch Sizes: A simulation based study on how equally sized batches affect production planning
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.
2017 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

Volvo Trucks is one of the world’s largest truck manufacturers, with a cab production plant located in Umeå, Sweden. The variation in batch sizes of the different components causes variation in the length of the production plan of subparts, and thus variation in production lead times. This project aims to examine how equally sized batches affect the length of the production plan, and what batch size is optimal to achieve efficient production planning. The examination was conducted with respect to lean principles and a mathematical model was built to simulate the use of different batch sizes. In order to run the simulation, both historical and new data was used. Parameters interesting to examine for the result are the length and variation of the production plan, number of set-ups, production frequency, inventory levels and the annual production. A batch size of 2.0 hours is optimal as the length of the production plan then varies the least in the allowed interval. Equally sized batches exclusively were not found to contribute to a more efficient production planning. Smaller batch sizes in combination with equally sized batches were however shown to decrease the variation in the production plan, and to result in increased stock turnover and decreased inventory levels.

Abstract [sv]

Volvo Lastvagnar är en av världens största lastbilstillverkare, med en fabrik för tillverkning av hytter placerad i Umeå. Variationen i orderstorlekar för olika komponenter orsakar variation i längden av produktionsplanen, vilket i sin tur leder till varierade ledtider. Detta projekt syftar till att undersöka hur utjämnade orderstorlekar påverkar längden av produktionsplanen och vilken orderstorlek som är optimal för en effektiv produktionsplanering. Projektet utfördes med hjälp av leanprinciper och en matematisk modell av produktionen byggdes för att simulera användningen av olika orderstorlekar. För att köra simuleringen användes både historiskt och nytt data. Intressanta parametrar för resultatet är längden och variationen i produktionsplan, antal verktygsbyten, produktionsfrekvens, lagernivåer och årlig produktion. En orderstorlek på 2,0 timmar är optimal eftersom längden på produktionsplanen då har minst variation inom det tillåtna intervallet. Enbart jämna orderstorlekar visade sig inte bidra till en effektivare produktionsplanering, men mindre orderstorlekar i kombination med jämna orderstorlekar visade sig minska variationen i produktionsplan och resulterade i ökad lageromsättning samt minskade lagernivåer.

Place, publisher, year, edition, pages
2017. , 37 p.
Keyword [en]
Optimization, batch, leveling, simulation
National Category
Mathematics
Identifiers
URN: urn:nbn:se:umu:diva-137306OAI: oai:DiVA.org:umu-137306DiVA: diva2:1117835
External cooperation
Volvo Group Trucks Operations
Educational program
Master of Science in Engineering and Management
Supervisors
Examiners
Available from: 2017-06-30 Created: 2017-06-29 Last updated: 2017-06-30Bibliographically approved

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Optimization of Batch Sizes(1615 kB)18 downloads
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CiteExportLink to record
Permanent link

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Citation style
  • apa
  • harvard1
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
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  • sv-SE
  • Other locale
More languages
Output format
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