The selection of the production layout is never an easy task. Even with the best machinery, handling systems and operators, the production rate may be different from the desired one if these are not positioned correctly. As a matter of fact, positioning a machine in unsuitable places or lengthening the path of an operator for the transport of materials could compromise the efficiency of an internal production system. For these reasons, the creation of an efficient production layout should never be underestimated, and it must always be structured appropriately. This process is quite long and involves many people as well as quite few data to collect, thus during the internship it was broken down into smaller consecutive steps. The case study for this dissertation is Elettrotec S.r.l., an Italian manufacturing company specialized in the design, assembly and sale of pressure switches, flow switches, level switches and thermostats. For this company, the project presented in this thesis is part of a bigger plan that includes the re-organization and modernization of the business structure in order to be competitive. The following study aims to identify an alternative production layout solution to nonvalue-added activities process time and consequently increase the overall production capacity. First, the arrangement of the departments must be analyzed in order to simplify the materials flow, production lead time and activity management. After analyzing the current production flow, this project focused be on the company’s most important products. For each of them, this study took into consideration all the aspects that can influence the various assembly phases (e.g. transport of materials or products). To develop a new production layout, the production process of the most important products was then mapped using the Business Process Mapping Notation. Following the production flows analyses, some considerations arose, and some possible changes were proposed. For each proposal, this study highlighted its strengths and weaknesses and each solution was compared using a qualitative method (the Analytical Hierarchy Process). Finally, the dissertation proposed possible future actions that could be implemented to further improve the business process.
La selezione del layout di produzione non è mai un compito facile. Anche con i migliori macchinari, sistemi di movimentazione e operatori, il tasso di produzione potrebbe essere diverso da quello desiderato se questi non sono posizionati correttamente. Infatti, posizionare un macchinario in un luogo non idoneo o allungare il percorso di un operatore per il trasporto di materiali potrebbe compromettere l'efficienza del sistema di produzione interno. Per questi motivi, la creazione di un layout produttivo efficiente non deve mai essere sottovalutata e deve sempre essere strutturata in modo appropriato. Questo processo è piuttosto lungo e coinvolge molte persone, nonché molti dati da raccogliere, quindi durante questo stage, il processo è stato suddiviso in piccoli passaggi consecutivi. Il caso studio di questa tesi è quello della società Elettrotec S.r.l., un’azienda manufatturiera specializzata nella progettazione, assemblaggio e vendita di pressostati, flussostati, livellostati e termostati. Il progetto di questa ricerca si inserisce all’interno di un più ampio programma di riorganizzazione e modernizzazione delle strutture aziendali per mantenere alta la competitività. Il seguente studio ha lo scopo di identificare un layout ottimale per migliorare i tempi del processo e di aumentare di conseguenza anche la capacità produttiva. Dopo una prima fase di analisi generale, sono stati studiati i prodotti più importanti per l’azienda e, per ognuno di essi, sono stati considerati tutti gli aspetti che possano influenzare le varie fasi di assemblaggio (es. trasporto dei materiali o dei prodotti). Per sviluppare un nuovo layout produttivo è stato mappato il processo di produzione dei prodotti più importanti utilizzando il Business Process Mapping Notation. Dopo aver analizzato nel dettaglio i flussi produttivi sono state effettuate alcune considerazioni sul posizionamento attuale dei reparti, e sono state proposte alcune possibili modifiche del layout. Per ogni proposta sono stati descritti i punti di forza e di debolezza, e per concludere le alternative sono state confrontate utilizzando un metodo qualitativo (l’Analytic Hierarchy Process). Infine, sono state proposte delle possibili future azioni di sviluppo utili per migliorare ulteriormente il processo aziendale nella prospettiva di medio lungo termine.
Optimization of facility layout : production flow analysis of Elettrotec S.r.l.
FEDERICI, ALESSANDRO
2018/2019
Abstract
The selection of the production layout is never an easy task. Even with the best machinery, handling systems and operators, the production rate may be different from the desired one if these are not positioned correctly. As a matter of fact, positioning a machine in unsuitable places or lengthening the path of an operator for the transport of materials could compromise the efficiency of an internal production system. For these reasons, the creation of an efficient production layout should never be underestimated, and it must always be structured appropriately. This process is quite long and involves many people as well as quite few data to collect, thus during the internship it was broken down into smaller consecutive steps. The case study for this dissertation is Elettrotec S.r.l., an Italian manufacturing company specialized in the design, assembly and sale of pressure switches, flow switches, level switches and thermostats. For this company, the project presented in this thesis is part of a bigger plan that includes the re-organization and modernization of the business structure in order to be competitive. The following study aims to identify an alternative production layout solution to nonvalue-added activities process time and consequently increase the overall production capacity. First, the arrangement of the departments must be analyzed in order to simplify the materials flow, production lead time and activity management. After analyzing the current production flow, this project focused be on the company’s most important products. For each of them, this study took into consideration all the aspects that can influence the various assembly phases (e.g. transport of materials or products). To develop a new production layout, the production process of the most important products was then mapped using the Business Process Mapping Notation. Following the production flows analyses, some considerations arose, and some possible changes were proposed. For each proposal, this study highlighted its strengths and weaknesses and each solution was compared using a qualitative method (the Analytical Hierarchy Process). Finally, the dissertation proposed possible future actions that could be implemented to further improve the business process.| File | Dimensione | Formato | |
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Descrizione: Optimization of facility layout: production flow analysis of Elettrotec S.r.l.
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https://hdl.handle.net/10589/153624