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Flow Mapping and Process Development of CKD Door Production: A Simulation Study
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]

This thesis work was conducted at Volvo GTO Ume°a, a truck cab manufacturingplant, to investigate the production flow of doors sold as parts or to other factories,called CKD doors. The focus of the investigation was to, based on a flow mapping,conduct a cost analysis of the current production flow of CKD doors and to investigatethe possibilities of implementing cost reducing production changes.The investigation demonstrated that there are a lot of non-value adding activities inthe current production flow of CKD doors, resulting in unnecessary costs and longlead times. Based on the result from the flow mapping, cost analysis and investigationsabout possible flow changes, a new production flow was developed. It wasfounded in thorough data gathering and interviews with key employees at di↵erentpositions at the plant.To investigate how well the new production flow can perform and how well it canmeet the production requirements of the factory, a simulation model was built. Threeimportant parameters were used to optimize the capacity. These were the intervalof main doors between every CKD door, the break-point for the conveyor right afterthe door line which control when CKD doors are allowed to be produced, and theextra number of main doors between two batches of CKD doors.The result of the simulation study shows that the production flow gives the highestoutput with the parameter settings, in the same order as above, of 3, 5 and 4. Withthese parameter settings, the production needs are met enabling the suggested newflow.Implementing the suggested production flow is possible and would lead to largecost reductions of SEK XXXX , or 9.2% of the total operational cost of CKD doors,whilst retaining the required production capacity.

Place, publisher, year, edition, pages
2019. , p. 48
Keywords [en]
Simulation, Flow Mapping
National Category
Mathematics
Identifiers
URN: urn:nbn:se:umu:diva-160120OAI: oai:DiVA.org:umu-160120DiVA, id: diva2:1324121
External cooperation
Volvo GTO Umeå
Educational program
Master of Science in Engineering and Management
Supervisors
Examiners
Available from: 2019-06-14 Created: 2019-06-13 Last updated: 2019-06-14Bibliographically approved

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CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf