Production layout, flow analysis and production control system simulation study for a new factory
Tuovila, Tomi Ali William (2019)
2019
Konetekniikka
Tekniikan ja luonnontieteiden tiedekunta - Faculty of Engineering and Natural Sciences
This publication is copyrighted. You may download, display and print it for Your own personal use. Commercial use is prohibited.
Hyväksymispäivämäärä
2019-06-14
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201906111877
https://urn.fi/URN:NBN:fi:tty-201906111877
Tiivistelmä
The subject company of this thesis is manufacturing different types of valve products in multiple locations worldwide. The company is constructing a new production facility and a part of the current factory operations are transferred to the new location. This thesis exclusively focuses on the design of this new factory. The three main goals of this work are 1) developing the best possible layout solution, 2) recognizing the main material flows of the new layout and 3) designing a new production control system for the new factory.
To find answers for these thesis problems, the following research methods were used: literature research, theme interview, Gemba walk, data sorting and simulation research. With the help of literature research, an excellent picture of the thesis’s topic area was created for the reader as well as for the thesis’s author. Theme interview and Gemba walk were performed as a part of the current factory research. The current factory research’s objective was to get familiar with factory’s daily operations and define the factory’s production operation’s pros and cons. As a final part of this thesis research, a simulation model was created of the new factory. The creation of the simulation model required data sorting for the data input to the model. With the help of the simulation model, the main research topics of this thesis were studied.
Answers were formed for all the main research questions during this thesis. Based on the thesis results and analysis, a material flow-oriented layout solution is the best option for the new factory. The material flows in this type of layout are mainly one-way and are quite similarly-sized throughout the factory. An inventory level-based pull system was found to be the best solution for this type of high-volume production factory. All these main question results are justifiable from a known literature point of view as well as from the current factory analysis point of view. The results were also analyzed thoroughly to get the most out of the results.
With the help of the simulation model, on top of researching the main questions, multiple numerical values of the new factory were studied. The targets for these numerical were set at the start of this thesis. Some of these numerical values were: the work-in-process in machining area, product throughput times and inventory levels. For the most part, all of these numerical targets were achieved during the simulation study.
To find answers for these thesis problems, the following research methods were used: literature research, theme interview, Gemba walk, data sorting and simulation research. With the help of literature research, an excellent picture of the thesis’s topic area was created for the reader as well as for the thesis’s author. Theme interview and Gemba walk were performed as a part of the current factory research. The current factory research’s objective was to get familiar with factory’s daily operations and define the factory’s production operation’s pros and cons. As a final part of this thesis research, a simulation model was created of the new factory. The creation of the simulation model required data sorting for the data input to the model. With the help of the simulation model, the main research topics of this thesis were studied.
Answers were formed for all the main research questions during this thesis. Based on the thesis results and analysis, a material flow-oriented layout solution is the best option for the new factory. The material flows in this type of layout are mainly one-way and are quite similarly-sized throughout the factory. An inventory level-based pull system was found to be the best solution for this type of high-volume production factory. All these main question results are justifiable from a known literature point of view as well as from the current factory analysis point of view. The results were also analyzed thoroughly to get the most out of the results.
With the help of the simulation model, on top of researching the main questions, multiple numerical values of the new factory were studied. The targets for these numerical were set at the start of this thesis. Some of these numerical values were: the work-in-process in machining area, product throughput times and inventory levels. For the most part, all of these numerical targets were achieved during the simulation study.