Reducing Internal Failure Quality Costs Using Plan-for-Every-Part Methods in High-Mix-Low-Volume Production Within a Large Manufacturing Company – A Case Study
Lampimäki, Juho (2018)
2018
Tuotantotalous
Talouden ja rakentamisen tiedekunta - Faculty of Business and Built Environment
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Hyväksymispäivämäärä
2018-06-06
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201805281874
https://urn.fi/URN:NBN:fi:tty-201805281874
Tiivistelmä
In high-mix-low-volume production, the variety of items handled can be significant. In environments with numerous items and lots of variation, flexibility is often required. Still, obtaining the flexibility efficiently requires using human workforce. When humans are part of processes errors are likely to happen. Having all relevant item data collected in one place, creating straightforward procedures and instructions for handling of different item groups and making sure they are followed decreases the risk of defects and errors.
In this thesis implementing Plan-for-Every-Part methods, a centralised database for item information is discussed in the context of a large manufacturing company having production that can be defined as high-mix-low-volume production. This is done to reduce internal quality costs due to material handling defects. For finding the ways to utilise Plan-for-Every-Part methods in the Case Company the quality costs from the year 2017 were analysed and the greatest cost sources were recognised. People holding responsible positions at the Case Company were interviewed for understanding the processes and finding improvement areas. The relevant material handling processes were also observed. The Case Company’s internal instructions and standard operating procedures were also assessed.
The quality costs caused by defected items accumulate due to machining rework (70 % of the total quality costs) and assembly rework (30 % of the total quality costs). The item group causing most of the quality costs are the end-products’ body parts. Reasons for body part defects are insufficient protection of items during moving, careless handling and impurities on workstations. For preventing these kinds of defects from happening a Plan-for-Every-Part data sheet sketch and a step by step implementation plan for it were created. A test was conducted for adopting the solution in use. The Plan-for-Every-Part data sheet was adapted for the use of internal logistics operations. The Plan-for-Every-Part data sheet will be used as a tool in process standardisation and item protection planning with the aim to reduce material defects.
In this thesis implementing Plan-for-Every-Part methods, a centralised database for item information is discussed in the context of a large manufacturing company having production that can be defined as high-mix-low-volume production. This is done to reduce internal quality costs due to material handling defects. For finding the ways to utilise Plan-for-Every-Part methods in the Case Company the quality costs from the year 2017 were analysed and the greatest cost sources were recognised. People holding responsible positions at the Case Company were interviewed for understanding the processes and finding improvement areas. The relevant material handling processes were also observed. The Case Company’s internal instructions and standard operating procedures were also assessed.
The quality costs caused by defected items accumulate due to machining rework (70 % of the total quality costs) and assembly rework (30 % of the total quality costs). The item group causing most of the quality costs are the end-products’ body parts. Reasons for body part defects are insufficient protection of items during moving, careless handling and impurities on workstations. For preventing these kinds of defects from happening a Plan-for-Every-Part data sheet sketch and a step by step implementation plan for it were created. A test was conducted for adopting the solution in use. The Plan-for-Every-Part data sheet was adapted for the use of internal logistics operations. The Plan-for-Every-Part data sheet will be used as a tool in process standardisation and item protection planning with the aim to reduce material defects.