Analysis of an assembly process of electric detonators with application of lean manufacturing

Abstract: The principles of lean manufacturing made known to the world with the success of Toyota haveproven to be exceptional way to reach manufacturing brilliance. In recent years these sameprinciples have been used in other industries where for example patients, services or informationflows instead of solid products.The purpose of this thesis is to identify improvement opportunities in the assembly process ofelectric detonators with application of lean manufacturing. Three different tools were used todiscover the areas of interests: 1. Value-stream mapping: To analyze the process on a macro level. 2. Process mapping: To analyze the processes on a micro level. 3. Spaghetti diagram mapping: To analyze the wastes built into the layout. In addition, simulation with VBA for Excel was used (where applicable) to explore the performanceand/or the possibility of suggested changes such as Kanban systems and new production orderpolicy.Suggested changes include new replenishment systems for company made materials to ensureavailability of these materials, elimination of non-value adding processes and justification ofincreased automation at vital processes. Furthermore, the possibility of changing the productionorder policy to assembly to order from assembly to stock was explored. Few of these changes requireinvestments in equipment and changes to current processes, for which a rough estimation of therequired costs are included.