Efficiency and Automation in the Interface between Airframe Development and Production : A study to identify and reduce time-consuming activities with focus on the methodology of In-Process Part Definition

Abstract: This thesis started as an initiative from one of the co-authors that previously worked at SAAB AB during summer 2018. During the summer she worked with the design process of In-process part Definition (IPPD) and an interest emerged for making it more efficient. The design process of IPPD (DPOI) is where a design article, designed in CATIA, become manufacturable and adapted for assembly. The DPOI can be seen as the interface between the department of Airframe development and Production at SAAB AB. The first step was to investigate the current DPOI and conduct a pre-study to find time-consuming activities.  The pre-study consisted of five interviews, an observational study and a time study were the aims was to collect employees' own opinions, approve a pre-defined workflow divided into twelve elements and find problem areas. Element 1.0-11.0 is tasks within the DPOI and element 12.0 is the first step in the review process called Checker. Element 4.0 and 8.0 were divided further into parallel activities where the operators in the time study performs either, e.g., E4.0 (macro) or E4.1 (manually). To find time-consuming activities a time study was performed. The authors of this thesis acted observers and clocked each element while three operators denoted A-C designed 24 IPPDs. The results from the time study showed that elements 1.0, 3.0, 4.1 and 7.0 were time-consuming and E4.1 had potential to become automated. The selection of 2-3 problems was carried out through two Weighted Sum Models (WSM) where criteria was defined and solutions was listed. Each solution was weighted to each criterion and got a total grade. The selected problems, based on the total grade, were: Documents and Combined macro. Documents and manuals for scenario 5, 6 and the entire design process of IPPD was developed to make new employees learning process more efficient. A draft macro for scenario 5 and new complete macros for scenario 1 and 6 was developed and used in the comparative study. The comparative study was conducted like the previous time study but instead the new developed macros was used to make E4.0 more efficient and eliminate E4.1. In the comparative study only E4.0 was clocked for all 24 IPPDs in the time study. The result showed that E4.0 has become average 60% more efficient for all IPPDs and the total time with the new developed macros for E4.0 vs E4.1 has become 14,3% more efficient. Problems and time-consuming activities has been found and improved. The performed comparative study shows that the DPOI can be minimized further in terms of time; there are possibilities to make more elements from the DPOI automated.