Analyses of main module with ergonomic aspects

Abstract: This report describes an in-depth study on the design regarding five process machines', within Tetra Pak Dairy and Beverage Systems AB, common platform called Main Module. It is an inferred issue in the already started Project Berlin that puts its focus on the ergonomic aspects of a new design. How should Tetra Pak Dairy and Beverage Systems AB design their new platform, with focus on ergonomics, but still reduce operating costs and lead-time?Our findings reveal that:- By continually working with modularization, in means of structuring the platform by function flow, the design has become more accessible. - The Main Module in project New Generation is a big improvement from earlier designs, but could be even more simplified. This would bring reduced material costs and also partake an additional ergonomic approach. - In the development of a good design and a usable unit, it is crucial to actually find the customer demands. More direct and regularly communications or studies is essential.- If TP D&B wants to be in the front of modularization the custom made modules needs to be minimized. To minimize, they will have to regard the claims with follow-up. - It is hard to work with optimizations on the Main Module when even the prototypes are delivered like orders. The prototype room doesn't work like it is supposed to. - Some recommendations from the Project ERA, Equipment Ergonomic Handbook, can be hard to follow. In this Master Thesis some new recommendations are defined. - According to studies with NASA-TLX, the heat exchanger is the most vital concern in ergonomics within assembling.- Bad ergonomics can be a result of not having high standards of quality. With the work of Lean production its essential to have continues quality checks.- With a focus on the assembling, the lead-time should be able to be reduced by simple design solutions and generate a total saving about 100 000 SEK per year.Drawing from the above findings, we believe that TP D&B should make a Best Case with the Main Module. They have already made some progress within the Project Berlin. Now time can be spent focusing on sub-modules and usability according this study.