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Author:Tervahartiala, Tero
Title:Manufacturing campus facility planning project
Tehdaskompleksin asemapiirroksen suunnitteluprojekti
Publication type:Master's thesis
Publication year:2013
Pages:83 + [18]      Language:   eng
Department/School:Koneenrakennustekniikan laitos
Main subject:Teollisuustalous   (TU-22)
Supervisor:Lillrank, Paul
Instructor:Kuska, Miroslaw
OEVS:
Electronic archive copy is available via Aalto Thesis Database.
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Location:P1 Ark Aalto  6294   | Archive
Keywords:facility planning
layout design
material flow analysis
automotive industry
manufacturing
materiaalivirta
tuotannonohjaus
Lean
asemapiirros
autoteollisuus
tuotanto
Abstract (eng): The objective for this thesis was to develop a campus layout to promote operational synergies between two currently separate manufacturing facilities in automotive and heavy industry branches.
This research implemented various tools of material flow analysis and basic simulation methods to create a layout proposition to decrease the distance travelled of material on the shop floor.
The framework created in this study could also be used as a source of inspiration in similar facility planning projects.

The theoretical part of this research highlights the importance of aligning business strategy with operations strategy and further with operational level decision making.
Meaning that the elements have to contribute to each other for a manufacturing company to be successful In addition lean philosophy is discussed and a frameworks and tools used in facility planning are evaluated.
The empirical part of this research focuses on mapping material flows in the two facilities of the case company and analysing the machine base on the shop floors of both facilities.
Based on this analysis a layout concept was developed that is supposed to increase the flow efficiency and safe shop floor space.

The results of this research indicate that there is indeed potential to shorten the material travel distance by 50% and significant surface area on the shop floor can be freed for other use.
Future research would include increasing the level of detail of the analysis and creating a more complete model of the manufacturing system to test the proposed layout.
Abstract (fin): Tämän tutkimuksen tavoitteena on kehitellä kahdelle tällä hetkellä erillään toimivalle tuotantolaitokselle yhteinen asemapiirros.
Uuden asemapiirroksen tulisi mahdollistaa tuotantoprosessien jakamisen ja täten tekisi molempien tehtaiden tuotannosta kustannustehokkaampaa.
Tutkimuksessa käytettiin yleisiä materiaalivirran analyysimenetelmiä ja yksinkertaista mallia tuotannon simuloimiseen.
Tämän tutkimuksen ratkaisumalli voi hyvinkin olla hyvä inspiraation lähde vastaaville tuotantolaitosten suunnitteluprojekteille.

Tutkimuksen teoriaosuudessa käsitellään yrityksen strategian ja tuotantosysteemin vastaavuuden tärkeyttä sekä lean-tuotantofilosofian peruskäsitteitä.
Lisäksi arvioitiin eri tuotantolaitosten kehittelyn ratkaisumalleja ja niihin liittyviä työkaluja.
Käytännön osuus keskittyy kyseessä olevien tuotantolaitosten materiaalivirtojen ja konekannan analysoimiseen ja tulosten perusteella uuden asemapiirroksen hahmottelemiseen.

Tutkimuksen tuloksena havaittiin, että materiaalin kulkema matka tehtaan lattialla voisi jopa puolittua tuotantoprosessien uudelleenjärjestelyllä.
Lisäksi havaittiin, että lattiapinta-alaa voitaisiin vapauttaa huomattava alue muuhun käyttöön.
ED:2013-12-09
INSSI record number: 48163
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