Assembly station development by flow analysis and systematic layout planning : Mapping of the current state of production, evaluation of alternatives and development of concepts for improved flow and flexibility

Abstract: Modul system HH deliver modular storage systems and electrical solutions that can be combined according to the customer's wishes. This thesis combines argues for the importance for companies to keep improving their organization and production to remain competitive. By relating to a holistic view of the development of production environments, the project focuses on improvements for efficiency and social sustainability in the development of production. The project became relevant as the company has discovered difficulties in balancing production in the event of capacity changes and wants to develop rational flows and increase its flexibility. The project is limited to exploring three assembly stations and the operations and flows that belong to the assembly. The project spiral's iterative 3-step development process was chosen for strategic planning. This methodology allowed the work to continue forward despite the lack of data. The first step deals with planning and processes where technology and users were examined. In this planning phase, a Gantt schedule was used in the ClickUp program to plan the project and to-do lists and deadlines could be set. A literature study was conducted to strengthen arguments and raise new ideas. The theoretical overview focuses on areas around production development with a focus on the development of layouts/assembly stations, psychosocial work environment and organizational management. In the second phase of the project, requirements and wishes were mapped. This was done together with the company, the results from this step were then used to evaluate concepts before detailed development. The project also has several parts of the framework that Muther & Wheeler developed called Systematic layout planning. It provided the tools to understand important connections through relationships and proximity analysis. These methods were also used to evaluate the results. Interviews, observations, and 3D modelling were also performed in this phase to gather information and to understand different production structures. Semi-structured interviews were performed with product managers, production designers, production planners. From these methods, I was together with some employees able to conclude that customer order-driven product development is the focus. That production places demand on rapid implementations in production and that modularity means great flexibility needs and fast lead times. We also found opportunities to minimize repetitive and time-consuming steps through development based on the operator's point of view. Concepts were developed through a development process based on proximity analysis, time studies and results from more subjective interviews. The concepts were then evaluated through an evaluation matrix based on formulated future requirements and wishes. The winning concept was developed in more detail and developed iteratively together with staff from the company. The final concept combines a new, more compact layout that considers proximity requirements between stations as well as flows of materials and operators. The final layout also introduces new types of material buffers and action proposals for improved collaboration and communication for increased flexibility.