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Manual Assembly Improvement In Make to Order Production
Jönköping University, School of Engineering, JTH, Industrial Engineering and Management.
2015 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesisAlternative title
Manual Assembly Improvement in Make to Order Production. (English)
Abstract [en]

Manual assembly systems are widely used for producing customized products in make to order production. Despite their competitive advantages, manual assembly systems bring several problems to the production organizations. Early identification of problems on the production floor is very important in order to keep production processes running smoothly and efficient. Hence, this research aims to increase the knowledge of understanding problems related to manual assembly systems in make to order production and develop solutions for the problems. To be able to reach the research aim, two research questions were formulated. While, the first question investigates the problems related to manual assembly systems in make to order production, the second question aims to develop possible solutions for the problems.

To be able to investigate the research problem in a real-life context, a single case study was performed at Volvo Powertrain F-Plant in Skövde, Sweden where there is a manual assembly of heavy duty diesel engine variants. In addition, existing literature was also investigated to make connections between the theory and the practice. As a result, the problems were revealed under six main categories as assembly processes, assembly operator learning, material handling, layout, ergonomics and information system. After revealing the problems, solutions were developed for each problem by using lean production principles and lean tools such as value stream mapping, standardized work. Moreover, other methods such as implementing kitting system, eliminating 7 waste in the production and implementing Takt time were also used to develop solutions. Based on the value stream mapping at the case company, improvements were developed and future state map was created for the case company. Evidently, the theoretical framework and the results from the empirical work were supported each other. At the end of the research, both research questions were answered and the aim of the research has been reached successfully.

The results of the research could be used as a guide for production organizations with similar production systems in order to identify and eliminate problems in manual assembly systems in make to order production. In addition, this study could be a basis to investigate the problems and their solutions in manual assembly systems in make to order production. The problems and solutions in manual assembly systems in make to order production could be extended by applying new theories and methods in the research area as a further research.

Place, publisher, year, edition, pages
2015. , 61 p.
Keyword [en]
Manual assembly systems, manual assembly, make to order production, lean production, lean tools, 7 waste of lean
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:hj:diva-27546ISRN: JU-JTH-PRS-2-20150004OAI: oai:DiVA.org:hj-27546DiVA: diva2:839512
External cooperation
Volvo Group Trucks Operations
Subject / course
JTH, Industrial Engineering and Management
Presentation
2015-05-28, E1405, School of Engineering, Jönköping University, Jönköping, 09:00 (English)
Supervisors
Examiners
Available from: 2015-07-03 Created: 2015-07-02 Last updated: 2015-07-03Bibliographically approved

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