This thesis work aims to put in practice the A3 model in Hinowa, a manufacturing company producing aerial platforms, tracked dumpers, and undercarriages. This lean tool was applied in two different assembly lines: E-boom and Dumper. Both the lines needed overtime to keep up with the production rhythm, due to the launch of new products. Through the A3 steps, the Lean methodology was pursued, implementing its main pillars to the assembly lines. In this way, it was possible to reduce the wastes and the time needed to carry out assembly activities. In the thesis work, the A3 model is developed into three main sections: 1. As-is situation definition for both the lines, with the identification of the problem. The main dimensions of the problem are identified, such as the overtime caused by wastes and inefficiencies. After the company targets are set, a detailed root causes analysis is carried out to understand the sources of the problems. 2. Data analysis and implementation of countermeasures: once collected data through time relief and assembly order, the countermeasures are set. In both line wastes are reduced, picking lists optimized, Pert diagram implemented to improve the timing of picking delivery, lines were balanced, and carts were designed to reduce the volume of pallets on the line. 3. Data monitoring and identification of follow-up actions are presented as key to pursue the improvement quest. To resume the results of this thesis work, the new design of the Dumper line led to an increase in production volume of 57%. While in the E-boom line, the total time needed to produce a machine was reduced by 26% on average. Through the A3 steps, it was possible to reduce wastes, redefine and standardize activities, eliminate non-value-adding activities, and balance the line according to the Takt times defined. These findings provide insights into how the A3 tool affects the performance of manufacturing firms leading them to achieve superior performances.
Questa tesi presenta l’implementazione del modello A3 in Hinowa, un’azienda manifatturiera leader nella produzione di piattaforme aeree, moto-carriole e sottocarri. Questo modello è stato implementato in due diverse linee di produzione: E-boom e Dumper. Per poter mantenere inalterato il ritmo produttivo giornaliero ,l’azienda è dovuta ricorrere agli straordinari, a causa dei rallentamenti derivati dalla produzione di due nuovi macchinari. Attraverso l’implementazione del modello A3 è stato possibile implementare la metodologia Lean in entrambe le linee di produzione, così da ridurre gli sprechi e il tempo di produzione necessario. Il modello A3 è così presentato: Descrizione della situazione as-is per entrambe le linee. E’ presentato il problema con le sue componenti principali: gli straordinari e le inefficienze. Dopo aver identificato gli obiettivi aziendali, è presentata l’analisi delle cause radice per comprendere l’origine dei problemi. Analisi dei dati e implementazione delle contromisure. Ottenuti i dati del rilievo tempi e dell’ordine di assemblaggio, sono presentate le contromisure. In entrambe le linee gli sprechi sono stati ridotti, le liste di prelievo ottimizzate, il Pert implementato per ottimizzare il tempo di arrivo delle liste, è stato bilanciato il carico di lavoro delle linee e progettati carrelli per ridurre il numero di pallet. Monitorare i dati e definire azioni correttive future è stato fondamentale per proseguire il miglioramento continuo. Per riassumere i risultati di questa tesi, la linea Dumper è stata modificata, portando a un aumento della produzione del 57%, mentre la linea E-boom ha ridotto il tempo totale di produzione per macchina del 26%, in media. Attraverso gli A3, è stato possibile ridurre gli sprechi, ridefinire e standardizzare le attività, eliminando quelle a non valore aggiunto e bilanciando le linee, rispettando i Takt time imposti. Attraverso questo lavoro si è dimostrato come il modello A3 è efficace nell’ accrescere le performance di un’azienda manifatturiera aumentandone le performances.
Continuous improvement of manual assembly line using A3 model : a case study in Hinowa
GOBBI, GIANMARCO;ZOFFOLI, TOMMASO
2019/2020
Abstract
This thesis work aims to put in practice the A3 model in Hinowa, a manufacturing company producing aerial platforms, tracked dumpers, and undercarriages. This lean tool was applied in two different assembly lines: E-boom and Dumper. Both the lines needed overtime to keep up with the production rhythm, due to the launch of new products. Through the A3 steps, the Lean methodology was pursued, implementing its main pillars to the assembly lines. In this way, it was possible to reduce the wastes and the time needed to carry out assembly activities. In the thesis work, the A3 model is developed into three main sections: 1. As-is situation definition for both the lines, with the identification of the problem. The main dimensions of the problem are identified, such as the overtime caused by wastes and inefficiencies. After the company targets are set, a detailed root causes analysis is carried out to understand the sources of the problems. 2. Data analysis and implementation of countermeasures: once collected data through time relief and assembly order, the countermeasures are set. In both line wastes are reduced, picking lists optimized, Pert diagram implemented to improve the timing of picking delivery, lines were balanced, and carts were designed to reduce the volume of pallets on the line. 3. Data monitoring and identification of follow-up actions are presented as key to pursue the improvement quest. To resume the results of this thesis work, the new design of the Dumper line led to an increase in production volume of 57%. While in the E-boom line, the total time needed to produce a machine was reduced by 26% on average. Through the A3 steps, it was possible to reduce wastes, redefine and standardize activities, eliminate non-value-adding activities, and balance the line according to the Takt times defined. These findings provide insights into how the A3 tool affects the performance of manufacturing firms leading them to achieve superior performances.File | Dimensione | Formato | |
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https://hdl.handle.net/10589/174399