Optimizing the process flow in heat treatment plant through value stream mapping via simulation : A case study at Volvo Group Trucks Operations

Abstract: Manufacturing companies deal with inefficiencies in production processes. To optimize the process is one solution to the problem. In the thesis it is shown how the optimization of process flow is done in order to increase the efficiency of production processes in furnaces of heat treatment plants. The purpose of this thesis is about analysing the process flow in a heat treatment plant and increasing its efficiency through value stream mapping via simulation. This gives a brief idea about the process flow in different furnaces and designing a simulation model for optimization of the process. The idea is to look into the process of furnaces, recipe of furnaces or other quality issues, which need to be worked on. There is another concern, to able to have the multiproduction of two different components i.e. gear and shaft production in same furnaces. On based of these challenges, an efficient solution is required to make the heat treatment plant more efficient at Volvo Group Trucks Operations. The empirical case study was made in heat treatment plant, over the period of five months. To investigate the process flow, material handling and production has done. Therefore, the results from the studies will provide the information and knowledge obtained from Kaizen events and simulation. However, there is always unexpected rise and fall in production rate, so the demand is to have efficient working atmosphere. The well-organized material supply system will lead to a reduced lead-time and reduce the cost of operation, which will help to keep inventory in order and optimize the process flow. The answer to the three research questions will give possible solutions to the aimed objectives. Finally, the results will show the bottlenecks and loss in waiting time. In this thesis it shows that Volvo Group Trucks Operations can do optimization in process flow of furnaces. There would be requirement of upgrading equipment’s and making process automation. The optimization would lead to benefits with reduction in process flow and labours on adopting automation.