This master thesis reports a real case study carried out in the Italian plant of Ingersoll Rand, a global market leader operating in the industrial sector. The project was launched by the company to satisfy the need for the implementation of a new assembly line. Indeed, following the shutdown of a plant in the Czech Republic, the Italian plant of the company was requested to sustain the entire Czech production of rotary compressors. Therefore, the project work consisted of the creation of a dedicated assembly line exploiting Lean thinking. In particular, the project followed the A3 steps, the problem-solving tool developed by Toyota. The analysis of the problem started with a pilot test of the assembly. The pilot test highlighted that a huge amount of time was wasted during the assembly. Therefore, targets were set together with the stakeholders towards the reduction of wasted time. The Ishikawa diagram and the 5 Whys Method allowed the identification and analysis of the root causes. Some countermeasures were developed to remove those root causes and to reach the targets. Lastly, a plan of implementation of actions was developed. The implementation of the complete assembly line is not included in this master thesis, since it will be concluded by 2023. Therefore, this master thesis does not contain the direct monitoring of results. However, the impact of each countermeasure was estimated. Estimated results show that the assembly line and proposed countermeasures are expected to successfully satisfy the must- have targets and some of the nice-to-have ones.
Questa tesi di laurea magistrale riporta un vero caso di studio realizzato nello stabilimento italiano di Ingersoll Rand, leader mondiale nel settore industriale. Il progetto è stato lanciato dall'azienda per soddisfare l’esigenza di realizzare una nuova linea di assemblaggio. Infatti, in seguito alla chiusura dell’impianto in Repubblica Ceca, l'impianto italiano è stato incaricato di sostenere l'intera produzione ceca di compressori rotativi. Pertanto, il progetto si propone di creare una linea di assemblaggio dedicata sfruttando la filosofia Lean. In particolare, il progetto ha seguito le fasi A3, lo strumento di problem-solving sviluppato da Toyota. L'analisi del problema è iniziata con un test pilota dell'assemblaggio. Il test pilota ha evidenziato che un'enorme quantità di tempo è stata sprecata durante l'assemblaggio. Pertanto, sono stati fissati gli obiettivi insieme agli stakeholders per la riduzione del tempo perso. Il diagramma di Ishikawa e il metodo delle 5 Whys hanno permesso l'identificazione e l'analisi delle cause primarie. Alcune contromisure sono state proposte per eliminare tali cause e per raggiungere gli obiettivi. Infine, è stato sviluppato un piano di attuazione delle azioni. L'implementazione della linea di assemblaggio completa non è inclusa in questa tesi di laurea, poiché sarà conclusa entro il 2023. Pertanto, questa tesi di laurea non contiene il monitoraggio diretto dei risultati. Tuttavia, l'impatto di ogni contromisura è stato stimato. I risultati stimati mostrano che la linea di assemblaggio e le contromisure proposte saranno in grado di soddisfare con successo gli obiettivi must-have e alcuni di quelli nice-to-have.
Developing an assembly line : the Ingersoll Rand Case
Grandi, Chiara
2021/2022
Abstract
This master thesis reports a real case study carried out in the Italian plant of Ingersoll Rand, a global market leader operating in the industrial sector. The project was launched by the company to satisfy the need for the implementation of a new assembly line. Indeed, following the shutdown of a plant in the Czech Republic, the Italian plant of the company was requested to sustain the entire Czech production of rotary compressors. Therefore, the project work consisted of the creation of a dedicated assembly line exploiting Lean thinking. In particular, the project followed the A3 steps, the problem-solving tool developed by Toyota. The analysis of the problem started with a pilot test of the assembly. The pilot test highlighted that a huge amount of time was wasted during the assembly. Therefore, targets were set together with the stakeholders towards the reduction of wasted time. The Ishikawa diagram and the 5 Whys Method allowed the identification and analysis of the root causes. Some countermeasures were developed to remove those root causes and to reach the targets. Lastly, a plan of implementation of actions was developed. The implementation of the complete assembly line is not included in this master thesis, since it will be concluded by 2023. Therefore, this master thesis does not contain the direct monitoring of results. However, the impact of each countermeasure was estimated. Estimated results show that the assembly line and proposed countermeasures are expected to successfully satisfy the must- have targets and some of the nice-to-have ones.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/191602