Dissertations / Theses on the topic 'Low volume industry'

Dans cette thèse, nous nous intéressons à la phase de montée en cadence dans le contexte de l’industrie de faible volume. Nos travaux se fondent sur des études de cas réalisées à Siemens ETHS, une entreprise produisant des disjoncteurs haute tension. Nous nous sommes tout d’abord intéressés aux problèmes rencontrés lors de la phase de montée en cadence car leur gestion est une activité majeure pendant cette phase. Nous avons établi des problèmes types. En parallèle, nous avons réalisé un état de l’art complet sur la question de la montée en cadence afin d’établir une cartographie de la littérature existante. Enfin, nous nous sommes concentrés sur les problèmes d’échange d’information et de coopération en examinant les interfaces, c’est-à-dire les liens et interactions existantes aux frontières entre différentes fonctions industrielles. Nous proposons un nouveau modèle d’interface ainsi qu'un outil d’audit que nous avons utilisé sur trois études de cas, ce qui nous permet de tirer des conclusions tant d’un point de vue pratique pour nos partenaires industriels que d’un point de vue académique
In this dissertation, we address the issue of production ramp-up in the context of the low volume industry. This dissertation builds upon case studies carried out at Siemens ETHS, a company manufacturing high voltage switchgear. We first focused on the problems encountered during the ramp-up phase, since fire-fighting (i. E. Problem handling) is a major activity during ramp-up. We identified problem types. Meanwhile, we realized a thorough state regarding the ramp-up issue, so as to provide a « map » of the existing literature. Finally, we focused on information exchange and cooperation problems. The approach taken is to focus on « interfaces », i. E. The links and interactions existing at the boundary of different industrial functions. We propose a new interface model and the corresponding auditing tool. The auditing tool was used on three different case studies. We draw valuable conclusions for our industrial partners but also outlined interesting results from a research point of view

Thesis (S.M.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering; in conjunction with the Leaders for Manufacturing Program, Massachusetts Institute of Technology, 2000.
Also available online at the MIT Theses Online homepage .
Includes bibliographical references (p. 80).
The industrial gas turbine (IGT) market is experiencing exponential growth where competition is based upon technical performance and time to market. Product sales are limited by the ability of the Original Equipment Manufacturer (OEM) to coordinate manufacturers and assemblers to deliver turbines to customers in a timely manner. The company's logistics and supply chain systems have evolved from a traditional low volume job-shop environment and must now cope with a marked increase in product demand. OEM's must now manage the manufacture and assembly of thousands of turbine parts across an international and complex supply chain in a robust and agile manner. This requires the effective integration of internal and external logistics, supply chain and engineering talent. Current performance has been plagued with poor sourcing reliability, low quality and exploding lead times. This has resulted in sluggish response to customer demand and loss in earnings. This thesis seeks to recommend inventory placement strategies to improve sourcing reliability while identifying root causes and recommending improvements. It will also address the importance of the time-value of material in addressing investment and materials management decisions.
by Miriam Park.
S.M.

Thesis (Ph.D.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering, 1998.
Includes bibliographical references (p. 117-119).
Low volume manufacturing has become increasingly important for the automotive industry. Globalization trends have led automakers and their suppliers to operate in developing regions of the world were economies of scale can not always be achieved. Niche markets for the performance/sport cars and some luxury sedans have been gaining economic importance, further fueling the need for developing more economic efficient low volume manufacturing operations. While low volume manufacturing has been the subject of much research, this has largely focused on flow optimization, inventory reduction and logistics improvements. Less attention has been paid to the subject of process technology choices. Identifying and employing optimal processing technology for low volume applications can reduce costs significantly. This thesis presents technical cost modeling as an effective methodology for examining low volume manufacturing cases and identifies typical areas of concern for low volume producers. General strategies for reducing the cost penalties associated with low volume production are also presented. Four cases are analyzed; Argentine engine valve manufacturing, Thai steering wheel manufacturing, automobile radiator manufacturing, and sheet metal stamping. These cases exemplify three of the most common issues affecting low volume manufacturing; the selection of optimal alternative manufacturing technologies, tooling related issues such as the optimal investment levels and the choice of tooling technologies, and the choice of automation levels. Results show that alternative process technologies may address low volume problems associated with long set-up times, poor equipment and tooling utilization and high tooling investment. The use of alternative tools which are less expensive, but have a shorter life are also potential solutions. Automation level optimization can be used to target the required output levels as well as affect the labor capital balance.
by Luis David German.
Ph.D.

Geometrical variation is an unavoidable aspect in all types of manufacturing that may, unless managed, risk failure in fulfilling product requirements which may result in rework, delays and bad publicity. The term geometry assurance includes the tools, methods and processes that can be utilized to manage the effects of geometrical variation and to ensure fulfillment of esthetical, functional and assembly requirements. While state of the art research in geometry assurance is extensively applied within the automotive and aerospace industries with great success, its application in low volume manufacturing of complex products remains limited. The shipbuilding industry is an example of such an industry, often manufacturing large and complex products in low quantities. Further, the shipbuilding industry has historically been labor-intensive and relied on craftsmanship throughout the product realization process. However, studies indicate that a technology-intensive development is crucial for companies in order to maintain market competitiveness. This transition places high demands on a well-established geometry assurance process in order to ensure successful assembly and fulfillment of product requirements.  In this thesis, a feasibility study is conducted on how geometry assurance may be applied in low volume manufacturing of complex products. By developing guidelines on how geometry assurance may be applied, the purpose is to improve geometrical quality throughout the product realization process and to reduce lead times, costs and increase assembly precision.  To explore the feasibility of geometry assurance in low volume manufacturing of complex products, a work structure consisting of three phases was established. In the first phase, a current state analysis of the collaboration partner Saab Kockums was conducted parallel to studying state of the art research in geometry assurance. In phase two, the state of practice of companies in the automotive and aerospace industries was studied in order to determine how they apply state of the art research. By interviewing industry specialists and combining gained knowledge from the first two phases, guidelines on how geometry assurance may be applied in low volume manufacturing of complex products was developed. In phase three, based on these guidelines, suggestions on how the geometry assurance process in pipe manufacturing at Saab Kockums can be improved was developed. The results of this study indicate that geometry assurance is applicable in low volume manufacturing of complex products. However, alternative methods may be required. Based on gained knowledge and insights from interviews with industry specialists, guidelines on how geometry assurance in low volume manufacturing of complex products may be applied are proposed. In order to improve the geometry assurance process in pipe manufacturing at Saab Kockums, this study proposes general guidelines for improvement along with a process and prototype measurement tool for the fitting-pipe methodology. The specially designed prototype measurement tool presents an alternative measurement method that can be used in cramped spaces where it is difficult to access with a 3D-measurement arm, the proposed primary measurement technique. In conclusion, this study indicates that geometry assurance is applicable in low volume manufacturing of complex products and suggests three methods for how it may be achieved. However, each of these methods needs to be further investigated in order to determine their applicability in other low volume manufacturing industries. Further, the prototype measurement tool and process for the fitting-pipe methodology indicates potential for improving the geometry assurance process in pipe manufacturing. However, further work is needed to complete the process for fitting-pipes and to finalize the prototype measurement tool for production use.

There are many challenges when automating industrial processes. Successful automation projects can lead to several benefits such as lower manufacturing costs, improved quality and reduced lead times. The purpose of this study is to identify the biggest challenges when automating processes within heavy industry and then, find ways to solve these. The study has an abductive approach, where focus has shifted between literature and empirical data. Empirical data has been gathered through a case study. The case study is carried out at a company that operates within heavy industry. It’s a pre-study before an automation project. The case study has followed methods presented in literature. Challenges that proved most difficult during automation within heavy industry were: Adapting a product for automatic manufacturing and product variations. The conclusion drawn from the results and experiences during the case study, is that the most comprehensive solution to these challenges is continuous improvements of products and processes.

This thesis investigates the possibility to adapt Overall Equipment Effectiveness (OEE), tothe development process in the shipbuilding industry.More specifically the development process wasdelimited to the phases; design, work preparation, production and verification.Ordinarily, OEE is a performance measurement for mass production. Itincludes aquality parameter which has been the focus of this thesis. Both literature review and case study investigation show that process quality is of critical importance in the shipbuilding industry because of the needs for dimensional accuracy and high-quality assemblage.The three main factors affecting process quality are;the flow of information between engineering phaseand productionphase, and the amount of rework and delays. The factors wereevaluated along an optimization method with a specific attention to process quality. Acase studywas conductedto confirm the relevance of the literature review on factors affecting process qualityand allowedto gather factors in process quality that are relevant to the industry.In light of those results, I re-developed a model providingnew measurement of what I call OPQE (Overall Process Quality Efficiency).This study contributes to a betterunderstanding of process quality in ETO(Engineering-To-Order)industries. Notably it shows how deviations that require rework and causesdelays are impacting process quality. It also shows that detecting errors early in the process of production is essential for insuring quality control. An error detected late affects negatively process quality and increases cost.

Standardization is Organizing and showcasing a manufacturing firm’s product or potentially benefits abroad are confronted with the choice of whether to institutionalize or adjust their product variants which simply means “one size fits all” method (Lundeteg, 2012). As industrial revolution was in peak many manufacturing industries around the world moved from mass production to mass customization. As per then, customers need was to gain a desirable product even if the lead time was higher than of buying a common product which everyone has.Main aim of the study is to re implement mass production in a firm where mass customization was adopted decades ago. As there are two categories of customers supporting both customized production and mass production, they need to adopt an innovative way without losing both types of customers. This report consist of the ways standardized production was done in the case company without affecting both types of customers and by decreasing lead time which was their main problem. The report consist detailed description of methods adopted for analyzing and how standardized production is effectively incorporated with customized production. Report also consist of quantitative data and qualitative literature support for analyzing and creating simulation model.Case study was also aiming at production systems in the company to understand the productions in deeper manner and how the new system could be effectively implemented in current situation. New proposal for standardized production was done based on the detailed study of factory layout and the products were proposed after detailed analysis of the quantitative data. Study was mainly concentrated on quantitative sales data analysis as the production is done base on make to stock and the customization is just done in cutting section. Analysis and simulation model creation was done in excel as the internal documents were done in excel and complex operations also is possible in excel.

Production system development is challenging for manufacturing companies, and development of HMLV production cells entails additional challenges. Thus, the aim of this study is to support the development of a HMLV production cell, and the following research questions were asked: RQ1: What are the challenges of developing a HMLV production cell? RQ2: What are the critical factors to consider when developing a HMLV production cell? RQ3: How can the development of a HMLV production cell be supported? A literature review in combination with a case study were performed to fulfill the aim and answer the research questions. The literature review was conducted to gain knowledge from previous studies, whilst the case study was performed to complement the theoretical findings. The selected case is the development of a HMLV production cell in the department of engine machining at Scania, which is planned to perform production activities for various departments of Scania. The primary data was collected through observations and interviews. The identified challenges of developing a HMLV production cell were production planning, utilization of equipment, product quality and material flow. The identified critical factors to consider when developing a HMLV production cell were production flexibility, production competence, production technology, pilot production, manufacturing strategy, order management system and standardization. The identified challenges of developing a HMLV production cell and the critical factors to consider when developing a HMLV production cell can support manufacturing companies by informing what challenges to expect prior to developing a HMLV production cell, and what critical factors can mitigate these challenges. Two ways of supporting the development of a HMLV production cell are recommended to Scania: creating a structured order management system and performing a pilot production for the milling operation of the core box reparation process. During this study, it was discovered that different HMLV production cells have different capabilities, challenges, and therefore also different critical factors. As such, recommendation for further research is to investigate how the development of different types of HMLV production cells can be supported by using a multiple case study research design, and to compare the challenges and critical factors for the development for the different types of HMLV production cells.

Dans cette thèse, nous nous interessons à la phase de montée en cadence dans le contexte de l'industrie de faible volume. Nos travaux se fondent sur des études de cas réalisées à Siemens ET HS, une entreprise produisant des disjoncteurs haute tension. Nous nous sommes tout d'abord interessé aux problèmes rencontrés lors de la phase de montée en cadence car leur gestion est une activité majeure pendant cette phase. Nous avons établi des problèmes types. En parallèle, nous avons réalisé un état de l'art complet sur la question de la montée en cadence afin d'établir une cartographie de la littérature existante. Enfin, nous nous sommes concentrés sur les problèmes d'échange d'information et de coopération en examinant les interfaces, c'est-à-dire les liens et interactions existantes aux frontières entre différentes fonctions industrielles. Nous proposons un nouveau modèle d'interface ainsi qu'un outil d'audit que nous avons utilisé sur trois études de cas, ce qui nous permet de tirer des conclusions tant d'un point de vue pratique pour nos partenaires industriels que d'un point de vue académique

碩士
中原大學
工業工程研究所
92
ABSTRACT This research studies a JIT delivery model for high variety and low volumn production in auto industry. This model can improve the logistics efficiency and effectiveness by reducing stocks and simplifying delivery operation based on information sharing, JIT philosophy, and vendor-managed inventory. Due to the information invisibility and lack of mutual understanding, the delivery information provided by automakers generally exceeds the real material requirement. Furthermore, in order to ensure the accuracy of material supply, automakers set up several checking gates in various delivery processes. This leads to high inventory and inefficient control in delivery processes. In the proposed approach, automakers provide suppliers the real-time production information that drives suppliers’ sequential delivery process on a JIT basis. Moreover, suppliers manage the automakers’ warehouse to ensure the sufficient supply of parts. This saves the automakers’ management effort on the inventory and delivery control. Case study shows the approach significantly reduces the inventory level and increase the efficiency of logistics.

碩士
國立虎尾科技大學
工業工程與管理研究所
100
Due to the increasing competition in the external environment and low entry level in the industry, more and more plate manufacturing companies are facing survival problem. In order to maintain competitive advantage in the market, these companies need to have outstanding performance. The performance of a company depends on its operation strategy. Therefore, the objective of this study is to investigate the performance difference between two plate manufacturing companies in the central region of Taiwan. The Analytic Hierarchy Process (AHP) is used to compare these two companies’ performance emphasis. The result shows that the one with better performance puts emphasis on financial performance, and the other puts more emphasis on customer dimension.

No
A conceptual design approach is an important stage for the development of a hybrid Knowledge-Based System (KBS) for Low Volume Automotive Manufacturing (LVAM). The development of a hybrid KBS, which is a blend of KBS and Gauging Absences of Pre-requisites (GAP), is proposed for LVAM research. The hybrid KB/GAP system identifies all potential elements of LVAM issues throughout the development of this system. The KBS used in the system design stage of the LVAM system analyses the gap between the existing and the benchmark organisations for an effective implementation through the GAP analysis technique. The proposed KBLVAM model at the design stage explores three major components, namely LVAM car body parts manufacturing perspective, LVAM competitive priorities perspective and LVAM lean environment perspective. Initial results reveal that the KBLVAM system has identified, for each perspective modules and sub-modules, the Problem Categories (PC) in a prioritised manner.
The financial support by the Malaysian Government, Universiti Malaysia Pahang and University of Bradford for this research is grateful acknowledged.

碩士
國立交通大學
管理學院碩士在職專班工業工程與管理組
96
As the progressing of global supply chain and the changing of consumer behavior, the manufacturing industries have to change their business process accordingly. The VMI (Vendor Managed Inventory) Approach, which has been implemented in the manufacturing industries for many years, has brought great benefits to the EMS (Electronics Manufacturing Service) industry. The inventory was greatly reduced and the cash flow was much more increased. In recent years, HMLV (high mix low volume) production model arises and LMHV (low mix high volume) production model is replaced. When VMI approach is to be implemented by manufacturing companies, it is to reconsider how to have the partners, including suppliers and the channels cooperate with each other so as to expand the effects of implementing the VMI approach. This research is to study the critical successful factors of implementing VMI and the selection index of the suppliers. The EMS industry was used as an example, under HMLV production model, through questionnaire survey, in this paper, We found that： 1. “Quality” is still the most important factor when VMI approach is to be implemented. ”Delivery” is the second one. 2. The critical successful factor of implemented VMI for EMS industry and their suppliers depends on the resolution of how the VMI approach was executed. 3. The first-tier supplier of EMS industry has had the capability to execute the VMI under HMLV production model; there is no obvious difference between EMS industry and other industries in selecting their supplier under the HVLM (high volume low mix) production model.