The master thesis focuses on the implementation of SMED, a Lean Thinking tool, within a supplier of components for the Automotive sector. The supplier taken into consideration is Officina Meccanica Zanotti, which supplies turned components to VHIT, a company that assembles vacuum and hydraulic pumps. The project analyzes two specific families of components, pistons and valve holders, which are turned on a multi-spindle mechanical lathe. The thesis has been structured following the A3 Model, a problem-solving procedure invented by Toyota. The first part describes the problem by reporting how much the machine downtime due to setups affects the analyzed lathe. Subsequently, the average component changeover downtimes are calculated and the must-have and nice-to-have objectives are set on the average machine downtime and process variability. Subsequently, the analysis of the causes that determine inefficiencies in the setup process is performed, to then provide some countermeasures to improve and reduce machine downtime. Finally, machine downtimes are recalculated considering the improvement actions, to compare the average times obtained with the AS-IS situation and with the targets set. Thanks to the implementation of SMED, we have achieved a decrease in machine downtime, which, depending on the component change, ranges from 30% to 37%, also reducing process variability by up to 68%. All this favors the flexibility of the supplier to optimize the supply chain between Tier 1 and Tier 2.
La tesi si focalizza sull’implementazione dello SMED, strumento della Lean Thinking, all’interno di un fornitore di componenti per il settore Automotive. Il fornitore preso in considerazione è Officina Meccanica Zanotti, il quale fornisce componenti torniti a VHIT, azienda che assembla pompe del vuoto e idrauliche. Il progetto analizza due specifiche famiglie di componenti, pistoni e portavalvole, le quali vengono tornite su un tornio meccanico plurimandrino. La tesi è stata strutturata seguendo l’A3 Model, una procedura di problem-solving inventata da Toyota. Nella prima parte viene descritto il problema riportando quanto il tempo di fermo macchina dovuto al setup incida sul tornio analizzato. Successivamente vengono calcolati i tempi di fermo macchina medi per il cambio componente e vengono posti gli obiettivi must have e nice to have sul tempo medio di fermo e sulla variabilità del processo. In seguito viene eseguita l’analisi delle cause che determinano inefficienze nel processo di setup, per poi fornire alcune countermeasures per migliorare e ridurre il tempo di fermo macchina. Infine vengono ricalcolati i tempi di setup considerando le azioni migliorative, così da confrontare i tempi medi ottenuti con la situazione AS IS e con i target imposti. Grazie all’implementazione dello SMED abbiamo ottenuto una diminuzione del tempo di fermo macchina che, a seconda del cambio componente, va dal 30% fino al 37%, riducendo anche la variabilità di processo fino al 68%. Tutto questo è andato a favore della flessibilità del fornitore in ottica di una ottimizzazione della supply chain tra Tier 1 e Tier 2.
Upstream lean implementation : a SMED optimization of supplier's production flow
Melegatti, Alberto
2020/2021
Abstract
The master thesis focuses on the implementation of SMED, a Lean Thinking tool, within a supplier of components for the Automotive sector. The supplier taken into consideration is Officina Meccanica Zanotti, which supplies turned components to VHIT, a company that assembles vacuum and hydraulic pumps. The project analyzes two specific families of components, pistons and valve holders, which are turned on a multi-spindle mechanical lathe. The thesis has been structured following the A3 Model, a problem-solving procedure invented by Toyota. The first part describes the problem by reporting how much the machine downtime due to setups affects the analyzed lathe. Subsequently, the average component changeover downtimes are calculated and the must-have and nice-to-have objectives are set on the average machine downtime and process variability. Subsequently, the analysis of the causes that determine inefficiencies in the setup process is performed, to then provide some countermeasures to improve and reduce machine downtime. Finally, machine downtimes are recalculated considering the improvement actions, to compare the average times obtained with the AS-IS situation and with the targets set. Thanks to the implementation of SMED, we have achieved a decrease in machine downtime, which, depending on the component change, ranges from 30% to 37%, also reducing process variability by up to 68%. All this favors the flexibility of the supplier to optimize the supply chain between Tier 1 and Tier 2.| File | Dimensione | Formato | |
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2022_4_Melegatti.pdf
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https://hdl.handle.net/10589/188129