Pre-study on Marine-completion at Scania Engine

Abstract: This study has been conducted at Scania Engine Assembly, in particular in an production area that produces Marine Engines. Scania always strives for continuous improvement and the purpose of this study has been to create an overview of the production area Marine-completion, where the marine components are assembled. The goals were to create a current state analysis, propose a future state analysis and propose suggestions of solutions for improvement of Marine-completion. The research question was: How can the strategies for the current state analysis be chosen, used and analyzed in order to accomplish a successful current state analysis?. The research methodology in this study was conducted using qualitative and quantitative research strategies, where both primary and secondary data were collected. The theoretical framework was divided into four subsections: Production systems, project management, technical solutions of today and supporting literature for solutions. The main method of this study was collecting data. The data included layout of the production, assembly times, quality deviations, engine variant classifications, Value Stream Mapping, Safety, Health and Environment related deviations and costs. Based on the current state, a future state was developed. The results of the current state analysis was that there are a total of 20 main variants of marine engines which have different assembly times. The assembly time can vary from approximately 45 minutes to 3 hours and 35 minutes for straight engines and approximately 4 hours to 8 hours for V8 engines. The mean results from Value Stream Mapping concluded a distribution of 40 percentage Value Adding and 60 percentage Non-Value Adding, where the largest waste from Non-Value Adding activities was bringing parts. Most of the quality deviations were caused by the method, where the biggest problem was regarding "tool insufficiency". Safety, Health and Environment related deviations were identified, where the largest problems were "risk". The future state analysis ended up in three cases, which explains the possible savings and future states. The Failure Mode and Effects Analysis resulted in 7 failure modes, where "Engine-card missing tasks/parts" had the largest rating. The suggestion of solutions resulted in a new layout, new routines with the engine-cards with digital screens and some other smaller suggestions. This study concluded in three main suggestions of solutions about "Newlayout at Marine-completion ", "Digital screens at each station" and "Continuous update of enginecards", which resulted in three assignment directives that Scania can further work with in the future.