Strategy for automation and layout change in production systems

Abstract: The main objective of this thesis is to identify changes in Level of Automation (LoA) and layout which are correlated. The thesis is aiming to contribute in the progressing research in automation with a practical aspect which is important to manufacturers. A case study was conducted at Parker Hannifin since research material from 2007 was available of this production system. Data from two different points in time is a necessity to observe any correlation in LoAand layout changes. The thesis is also meant to document the production system at Parker Hannifin. The research questions which will be attempted to answer are the two following:  How does an increase of LoA affect the layout?  Is there a specific point in the LoA where the layout changes dramatically?  What improvements can be made to secure quality in Parker Hannifin’s production system? The DYNAMO methodology has been developed to measure and obtain an accurate picture of information flow and automation in production systems. The DYNAMO methodology uses a reference scale to measure LoA. This scale is divided into two parts, mechanical and cognitive, as both areas are considered when automating a production system. It proved to be an effective and objective technique to measure ParkerHannifin’s production system and data could be analyzed and compared to the previous study from 2007 ofthe same production system. The result from the case study at Parker Hannifin showed that the total LoA had increased and the layouthad changed, however the two alterations were not correlated. The Parker Hannifin case was further analyzed and one other experience from Sandvik was illustrated to draw the conclusion that there is a specific point in the LoA where the layout changes dramatically. (1) A mechanical LoA alteration betweenvalue 1 and 4 does not in itself involve a layout change. (2) Alterations in which LoA increases to 5, 6 or 7will most likely be followed by a layout change. Exactly how the increase of LoA affects the layout is hard to tell. Layout changes due to LoA are an issue of factory space and material flow. Since layouts should be compatible with current production systems, LoAchanges which infer in the production system might need a different space to be situated in, be it more space, less space or just a diverse positioning. Since cognitive LoA changes more frequently require equipment small in size, they are assumed to seldom cause layout changes. Recommendations that have been specifically stated to improve the production system at Parker Hannifin:  Make DFA a standard procedure  Workshop for designers and assemblers to collaborate  Designers join assembly line for half a day for assembly system understanding Color coding of slides to eliminate mistakes  Place instructions visibly for assemblers to easily access at all times to eliminate mistakes Using DFA at the developing stage for all valves is particularly important to minimize the costs and quality issues and ensure a smoother assembly.