Design and conceptual implementation of an improved pre-batch polymer handling process

Abstract: This thesis is a collaborative project between the division of Production and Materials Engineering and Trelleborg AB. The aim of the thesis is to analyse the current pre-batch polymer handling process, assess the current process from a Lean perspective, and provide a new handling process which is more effective in terms of capacity, operator time, forklift transportation and traceability. The current situation was first analysed, using both quantitative and qualitative methods. In order to find the most suitable production flow, two different solutions were developed. One of which had buffer storage, and one which did not have buffer storage. These two solutions were then compared on a number of criteria and finally the production flow with buffer storage was determined most suitable. To determine the credibility of the solution, the most critical components were prototyped, with successful results. The recommended solution leads to a reduction of forklift transportation by 69% and a reduction of time spent cutting polymer by 60%. Furthermore, the new production flow greatly improves operator ergonomics and enables the possibility of running three shifts instead two.