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.