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Storage prognosis of large components during the peak period at Siemens Hengelo

Hanoun Saado, A. (2017) Storage prognosis of large components during the peak period at Siemens Hengelo.

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Abstract:In order to meet the high demand in the last quartile of 2016 and in 2017 an extra production area had to be created. The management decided to empty hall 50 and using it for the most for production. The shelves with small components and the large special components on the ground in hall 50 were send to an external storage in Denekamp. These large special components are not necessary needed in the production but are needed occasionally for different processes, like testing. Until now there is no tool or system that would help to determine the amount of storage area during a certain time period. In the past it was not needed due to a lot of space and a shortage of storage area was never a problem. But now there is going to be needed an extra production area of 1200 m2, therefor storage area probably will be scarce. Obviously it is important to map the total required storage, determine the available storage and check whether there is a shortage of storage area during the peak to see which problems will approach. First a list of large components which are needed for the products at Siemens Hengelo which probably will be stored in hall 50. A list for the components of the gas turbine 600 (GT600) and the gas turbine 400 (GT400) has been made. The components for gas turbine 100 are assumed to be the same as the components for the GT400 and the same for counts for the components of the gas turbine 700 and gas turbine 600. The compressors are neglected in the first step to simplify the problem. After the lists are complete the dimensions and weight for these components are identified. This is done with the data base of Siemens Hengelo, where the all the information about the components could be found of old projects. The dimensions of the large components of different units are in general equal and could be used for projects in the future. To be able to determine the required storage for the components of the product, the production for the gas turbines should be known and understood. The sequence in which the components will be needed in production is determined. The available space for storage is depended of a couple of assumptions. Until The only unknown variable is the delivery of the components. The first Storage prognosis consists of a timescale horizontally and start dates of projects vertically where everything was filled in manually. In this prognosis it is assumed that every components arrives one week too early, hence it should be in stored in hall 50 for one week before it goes to the production. The result of this was a shortage of 412 m2 in week 11 of 2017. The assumption of delivering all components one week before they are needed is cancelled due to the management, they set a goal to let deliver all large components Just In Time (JIT). This does not solve the scarcity of storage area. Even if the large components arriving JIT the byproducts of the large products requires a lot of storage area. This count for the support beams of the GT600 which are needed in week 4 till week 6 but will be delivered in week one with the baseframe which is needed in the first week. The same applies for the Bleed air duct which is a byproduct of the core engine and the material package of the enclosure. In the new Storage Prognosis the JIT policy will be added. Also a possible external storage will be added to the Storage Prognosis in case there is a shortage of storage in hall 50. The Storage Prognosis is continue being improved to get more accurate results and changing the input effortless. After adding the JIT policy the shortage is vanished away, see figure 7. Different scenarios could be easily compared to each other due to the effortless adaption in the Storage Prognosis, see table 5 for the results of different scenarios. After the basis for the Storage Prognosis is completed, the input had to be verified. For the Storage planning stands that the accuracy is depending on the input. The verification of the Storage Prognosis implicates the accuracy of the input values, the correctness of the assumptions and checking the model of the Storage Prognosis. A final Storage Prognosis is made with all the information that is gathered during the internship. An addition to the graph is an extra line which is the summation of the required storage and external storage. This graph shows that if the managements succeeds the JIT policy, there will not be needed an external storage until Augustus 2017. The required storage and the storage which probably goes to the external storage are 581 m2.
Item Type:Internship Report (Master)
Siemens Hengelo, the Netherlands
Faculty:ET: Engineering Technology
Subject:52 mechanical engineering
Programme:Mechanical Engineering MSc (60439)
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