Development of a material handling process and layout for
the P356 mirror assembly at Schefenacker SVSA: focus on lean
thinking, work environment and quality technology management

Abstract: Schefenacker Vision System Australia Pty Ltd (SVSA) is one of 30 companies
in the Schefenacker International group, which is the leader in rear vision
mirror manufacturer with a 30 percent market share of the world market.
SVSA in Adelaide employs over 600 people and the turnover for 2005 was 178
MAUD.

This thesis project came about since Schefenacker in Adelaide was going to
produce the rear vision mirror for the new Ford Super Duty Truck 2008, with
code name P356. Schefenacker desired an optimal material handling process
for this complex P356 production. This resulted in cooperation with the
University of South Australia and Luleå University of Technology in Sweden
and this master thesis project arose.

Focus has been put on what could be done in a near future since it felt
important to have recommendations that could be put into practice within
the close proximity of launch and production. Great importance has been on
integrating the employees’ opinions into the development and result of this
process.

A project cycle method was developed to carry out this thesis work, since
it was necessary with a primary method which could manage a constant flow
of new information. The model was developed with inspiration from the
Deming wheel: plan, do, act and learn, together with Ranhagen’s spiral
model: a process should precede several laps before finish. The philosophy
Lean thinking has played an important roll throughout the process.

Qualitative facts are the base of this project. The information was
gathered through literature studies, a questionnaire, observations and
interviews with concerned workforce. The survey questionnaire was carried
out in the assembly area of the P356 mirror’s predecessor P131. The result
from the P131 study has been working as a foundation during the entire
project. The authors have been guided for comprehension about which areas
improvements would be desirable. The result is also presented in an
individual report, consisting of recommendations on how a more efficient
production and a better work environment can be achieved at the P131 area.
Benchmarking studies at Electrolux, Mitsubishi, Holden and Philmac have
been carried out which resulted in greater comprehension of different
possibilities concerning material handling.

A Specification of requirements for an optimal material handling process
with belonging layout was developed. Different layout alternatives with
diverse agendas were developed and later on compared. This resulted in a
final layout proposal combined of two alternatives, with core focus on
safety, minimised material handling and quality issues.

In the thesis suggestions can be find about of how and where to store
material for the P356 production, which quantities to hold, efficient
transportation solutions, other improvement concepts and some warnings
concerning future hazard risks in the work environment. Several analysis
concerning the material handling processes and the work environment such as
NIOSH have been made. According to the authors current buggy runs should be
standardised and integrated with supplying the production systems.
Dedicated trolleys should be used within the system acting as storage since
they are space efficient and prevents double material handling. The
developed prototype concept “Ball table trolley” could be an asset in the
material handling process, if developed further, according to the thesis
authors.

The thesis is most useful for Schefenacker but can also contribute to other
companies within the automotive industry and in other industries. The
thesis could be helpful when planning an optimised material handling
process, planning the division of parts, planning methods of replenishing
parts and other aspects which are important when implementing a new
production and optimising an existing process. Hopefully will this thesis
trigger questions and create ideas when planning or analysing other
material handling processes.