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Go with the flow!:een onderzoek naar efficiëntieverbetering door lay-out ontwerp voor de assemblageafdeling van Ahrend Productiebedrijf Zwanenburg op basis van het lean productie concept

Japsers, Juul (2009) Go with the flow!:een onderzoek naar efficiëntieverbetering door lay-out ontwerp voor de assemblageafdeling van Ahrend Productiebedrijf Zwanenburg op basis van het lean productie concept.

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Abstract:Ahrend Productiebedrijf Zwanenburg (APZ) is not satisfied with the current performance of the assembly department. APZ assumes that the layout of the department affects this performance. The research goal is to give recommendations for the design of a layout for the assembly department of Ahrend Productiebedrijf Zwanenburg that leads to a better efficiency, based on the lean production concept. Lean production aims to achieve the highest quality with the lowest costs, with the shortest lead times by eliminating waste. Waste is any activity that doesn’t add value for the customer. Seven types of waste are distinguished. These are overproduction, waiting time, process, transportation, inventory, motion and defects. Waste at the assembly department of APZ cost APZ per year a small eight hundred thousand euros. Lean prescribes the use of a line layout to stimulate flow to reduce setups and to make sure you can see the value stream. At APZ the volumes of specific products aren’t large enough to justify a production line per product. In the current situation almost every product does have its own production line. To do achieve the benefits of a line layout, we recommend the use of Group Technology (GT) cells. By analysing the processing steps, products are being grouped into product groups. Every single group gets an own GT-cel or production line. A method is proposed to develop a new layout based on GT-cells. This method includes five steps. These steps are the grouping to production lines, the line balancing per production line, de adaption of the pre-assembly steps to the assembly line, the organization of the supply and the physical design of the layout. Customer demand is leading in lean production. The takt time indicates the rhythm of the production based on this customer demand. The assembly line is balanced on this takt time. The design of the pre-assembly steps is adapted to this. Grouping the products leads to six production lines. These are the lines for the office chairs, normal chairs, desks, screens, other lounge products and other chairs. When the method for developing a new layout is applied to the production line for the office chairs, we can obtain insight in the possible improvement for the assembly department. The current efficiency is 58%. The theoretical possible efficiency is 87% with the current level of output. A feasibility test shows that the efficiency can at least improve to 80%. These results should be possible at an area that is about 40% of the current layout. The main conclusion is that it is possible to improve the efficiency by designing a lean layout. This new layout design based on the lean production concept will lead to a higher flexibility in capacity, to a higher efficiency and an additional advantage is that the production can be arranged on a smaller area. We recommend APZ to implement the new layout for the office chairs and to use the proposed method for layout design for the other production lines. The new layout will also give directions for the future for implementation of new products.
Item Type:Essay (Master)
Ahrend Productiebedrijf Zwanenburg B.V.
Faculty:BMS: Behavioural, Management and Social Sciences
Subject:85 business administration, organizational science
Programme:Industrial Engineering and Management MSc (60029)
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