Package Concept for High Variation Products to Improve Production : Package Development and Implementation to Improve Production of Heavy and High Variation Products

Abstract: Within the Master’s program in mechanical engineering at Linköping University, this thesis project unfolds in collaboration with Metso Sweden, specifically at their Sala factory. Focused on addressing challenges in packaging processes for Metso’s VASA-line slurry pumps, the project endeavors to devise a concept that not only meets global shipping requirements but also enhances factory output. The research unfolds with an exploration of the background, emphasizing the complexities of manufacturing large-scale pumps for heavy-duty industries. Operating in 45 countries with a workforce of approximately 16,000 employees, Metso’s site in Sala specializes in pump production, particularly for the mining industry. The unique nature of slurry pumps, designed to handle liquid solutions containing solid particles, necessitates a tailored approach to packaging. The identified problem lies in the high variation of pump configurations, demanding flexibility in production and packaging. Currently, custom-made packages are crafted by experienced operators, who are lacking feedback on their performance. The packaging process involves standard pallets or custom-made packages, with the latter lacking standardization and documentation, introducing uncertainties in transport. This study aims to improve overall efficiency at Metso by addressing bottlenecks and knowledge gaps in packaging, focusing on the VASA-line slurry pumps. The goal is to present a concept that aligns with global shipping requirements and has the potential to significantly increase factory output. The findings, supported by production analysis and a detailed implementation plan, estimating a 3.38-fold increase in current production capacity. The thesis utilizes production analysis methods in supporting product development and optimizing packaging processes. It further highlights the influence of global shipping requirements on production dynamics, necessitating additional steps in package assembly. With a focus on time rather than costs, this thesis positions itself as a practical guide for enhancing production efficiency within a constrained time frame. In summary, this thesis unfolds as an exploration of packaging challenges, offering tangible insights for product development in a production setting and package development, especially in the context of global shipping.