Our Master Thesis concerns the description of the project we did in Sun Chemical, the world's largest producer in the inks market. Our project has been carried out following step by step the A3 methodology. In particular, it was about a mapping and analysis of all the activities of the finished products warehouse in Caleppio 1 site, after a new management system implementation based on tablets introduction. The project had different objectives. First of all, Sun Chemical needed a study regarding how the different activities that require the usage of the new tablet were done, in order to understand where it was possible to exploit the tablet in a better way, where it was not used but had the potentiality to be used and where it required the need of some integration system. Secondly, from the mapping of warehouse activities, Sun chemical wished to have all the information such as the operator working time in each task and the overall saturation of operators, in order to understand whether there was the possibility of optimization, in terms of reduction of operator working time. The main problem we identified, as a result of the activities mapping, was the high saturation of shop floor operators, causing a high level of extra working hours. So, the consequent part of the project was the research of improvements in the activities, trying to reduce the working time of operators, keeping in consideration potential ways to better exploit the usage of the tablet in the warehouse activities. In particular, we found out ideas to improve some tasks, obtaining a significative reduction of the shop floor operator working time and consequently of the extra working hours. We made also an investment proposal, approved by Sun Chemical, about a complete changing of the configuration of the finished products warehouse, automating part of activities, through the installation of an AGV system, which will manage the shelves area of the warehouse, ensuring an economic saving and a safety improvement.
La nostra tesi di Laurea Magistrale riguarda la descrizione del progetto che il team ha svolto in Sun Chemical, il più grande produttore al mondo nel settore degli inchiostri. Il nostro progetto è stato svolto seguendo passo dopo passo la metodologia A3. In particolare, ha riguardato la mappatura e l’analisi di tutte le attività del magazzino prodotti finiti nel sito di Caleppio 1, in seguito all’implementazione di un nuovo sistema gestionale basato sull’introduzione di tablet. Il progetto ha avuto più obbiettivi. Prima di tutto Sun Chemical aveva bisogno di uno studio circa le diverse attività che richiedono l’utilizzo del tablet, per capire dov’era possibile sfruttarlo in un modo migliore, dove non era utilizzato ma aveva le potenzialità per essere usato e dove richiedesse l’ausilio di qualche sistema integrativo. Inoltre, dalla mappatura delle attività di magazzino, Sun Chemical desiderava avere tutte le informazioni come il tempo di lavoro degli operatori in ogni attività e la loro saturazione globale, per capire se ci fosse la possibilità di ottimizzazione, in termini di riduzione del tempo di lavoro degli operatori. Il problema principale che abbiamo identificato, risultato dalla mappatura delle attività, è stato un’alta saturazione degli operatori shop floor, che ha causato un alto livello di ore straordinarie. Quindi, la parte successiva del progetto ha riguardato la ricerca di miglioramenti nelle attività, cercando di ridurre il tempo di lavoro degli operatori, tenendo in considerazione potenziali modi per sfruttare meglio l’utilizzo del tablet nelle attività di magazzino. In particolare, abbiamo trovato idee per migliorare alcune attività, ottenendo una riduzione nel tempo di lavoro degli operatori shop floor e conseguentemente nelle ore straordinarie. Abbiamo fatto inoltre una proposta di investimento, approvata da Sun Chemical, riguardo un cambiamento totale della configurazione del magazzino prodotti finiti, automatizzando parte delle attività attraverso l’installazione di un sistema AGV, che gestirà l’area scaffali del magazzino, assicurando un risparmio economico e un miglioramento dal punto di vista della sicurezza.
Caleppio 1 warehouse : activities, analysis and optimization
BARTESAGHI, MARCO;BAJOCCO, FRANCESCA
2018/2019
Abstract
Our Master Thesis concerns the description of the project we did in Sun Chemical, the world's largest producer in the inks market. Our project has been carried out following step by step the A3 methodology. In particular, it was about a mapping and analysis of all the activities of the finished products warehouse in Caleppio 1 site, after a new management system implementation based on tablets introduction. The project had different objectives. First of all, Sun Chemical needed a study regarding how the different activities that require the usage of the new tablet were done, in order to understand where it was possible to exploit the tablet in a better way, where it was not used but had the potentiality to be used and where it required the need of some integration system. Secondly, from the mapping of warehouse activities, Sun chemical wished to have all the information such as the operator working time in each task and the overall saturation of operators, in order to understand whether there was the possibility of optimization, in terms of reduction of operator working time. The main problem we identified, as a result of the activities mapping, was the high saturation of shop floor operators, causing a high level of extra working hours. So, the consequent part of the project was the research of improvements in the activities, trying to reduce the working time of operators, keeping in consideration potential ways to better exploit the usage of the tablet in the warehouse activities. In particular, we found out ideas to improve some tasks, obtaining a significative reduction of the shop floor operator working time and consequently of the extra working hours. We made also an investment proposal, approved by Sun Chemical, about a complete changing of the configuration of the finished products warehouse, automating part of activities, through the installation of an AGV system, which will manage the shelves area of the warehouse, ensuring an economic saving and a safety improvement.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/154396