Analysis, Design, and Implementation of a training center for variable-speed drive assembly production : Case ABB Oy

In manufacturing constant developments in production, processes, and layouts are required to respond towards increased production volume, quality, and customer requirements while meeting production targets and objectives. The case company of this thesis is ABB Ltd Drives Manufacturing Unit, which specializes in variable-speed drive production. ABB has recognized the need for re-designing a new and effective training center that supports One-piece flow assembly production since the old model is based on a cell production method. The training center is used for the training and integration of the company's new and experienced assemblers. The aim of the research is to analyze the current training concept, design a new technical solution, and create a detailed implementation plan. Thus, the following research questions were developed: RQ1: How to develop and re-design a training center that supports the assembler for One-piece flow method production of variable-speed drives? RQ2: How to design and create the best possible layout and solution to guarantee safety, flexibility, ergonomics, clear flow, and the maximum utilization of space? RQ3: How to implement a training center that does not disrupt the main production lines and makes that way operations more efficient? To achieve the objectives, the waste, bottlenecks, and issues of the current design were first identified by observing the training process and organizing focus groups and workshops with the production line and logistics (customer), and with the project team. Work-time studies were also conducted to solve the flow, outputs, cycle time, and waste time of the current process. These data collection methods aided in identifying potential improvement opportunities for the new design. The layout design process was committed by utilizing Lean principles and the Systematic layout planning procedure. AutoCAD was used to create and map various layout structures, options, and alternatives. The design process required the tendering of two layout location options, which were solved using the quantitative multiple attribute decision-making method, Weighted decision matrix (WDM), with voting based on the scoring of various criteria and features. The result was a Flexible 6-phase U-model one-piece flow training center that allows assemblers to be trained in both one-piece flow and cell production methods. The new design's scope of work was delivered to the supplier, numerous negotiations were held to achieve the best final solution, and the new training center was ordered. In the end, a detailed implementation plan with an estimated schedule was created and a future action list was established. The new design fulfils the objectives and eliminates all issues, waste, and bottlenecks while also ensuring safety, ergonomics, flexibility, a clear flow, and a high-quality training process. With the new design, the efficiency, quality, and output of training and production operations will improve.Teollisuuden alalla tuotantojärjestelmiä, prosesseja ja layouteja on jatkuvasti kehitettävä sekä modifioitava reagoidakseen kasvaneisiin tuotantomääriin sekä laatu- ja asiakasvaatimuksiin ja saavuttaakseen asetetut tuotantotavoitteet ja päämäärät. Tämän opinnäytetyön toimeksiantaja on ABB Oy Drives Manufacturing -yksikkö, joka on erikoistunut taajuusmuuttajatuotantoon. Toimeksiantaja on tunnistanut tarpeen uuden ja tehokkaamman koulutuslinjan suunnitteluun One-piece flow malliseen taajuusmuuttajien kokoonpanotuotantoon, sillä vanha tuotantomalli perustuu solutuotantomenetelmään. Koulutuslinjaa käytetään niin uusien kuten jo talossa olevien vanhojen kokoonpanoasentajien koulutukseen ja integrointiin. Tutkimuksen tavoitteena on analysoida nykyinen koulutuskonsepti, suunnitella uusi tekninen ratkaisu ja laatia yksityiskohtainen implementointisuunnitelma. Tavoitteiden saavuttamista varten on kehitetty seuraavat kolme tutkimuskysymystä: RQ1: Kuinka kehittää ja suunnitella koulutuslinja, joka tukee asentajia One-piece flow malliseen kokoonpanotuotantoon? RQ2: Miten suunnitella ja luoda paras mahdollinen layout ja ratkaisu, joka takaa turvallisuuden, joustavuuden, ergonomian, selkeän virtauksen ja maksimaalisen tilankäytön? RQ3: Kuinka implementoida koulutuslinja, joka ei häiritse päätuotantolinjoja ja tehostaa siten operaatioiden tehokkuutta? Saavuttaakseen tavoitteet, nykyisen koulutuskonseptin aiheuttamat pullonkaulat, ongelmat ja hukka tunnistettiin ensin havainnoimalla koulutusprosessia ja järjestämällä haastatteluja sekä työpajoja tuotantolinjan ja logistiikan (asiakkaan) sekä projektiryhmän kanssa. Nykyisen prosessin virtauksen, ulostulon, tahti -ja hukka-ajan selvittämiseksi suoritettiin myös työaikatutkimuksia. Nämä tiedonkeruumenetelmät auttoivat kehitysmahdollisuuksien tunnistamisessa uutta ratkaisua varten. Layout suunnitteluprosessi toteutettiin Lean-periaatteita ja systemaattista layout suunnittelua käyttäen. AutoCAD layout suunnittelusovellusta käytettiin erilaisien asettelurakenteiden ja vaihtoehtojen luomiseen sekä kartoittamiseen. Suunnitteluprosessi edellytti kahden layout-sijaintivaihtoehdon kilpailuttamista. Lopputulos ratkaistiin äänestämällä kvantitatiivisen päätöksentekomatriisin (WDM) avulla, joka perustui eri kriteerien ja ominaisuuksien pisteytykseen. Tulokseksi saatiin joustava 6-vaiheinen U-mallinen One-piece flow koulutuslinja, jonka avulla asentajia voidaan kouluttaa sekä One-piece flow että solutuotantomallisesti. Uuden koulutuslinjan työn laajuus -dokumentti toimitettiin toimittajalle sekä lukuisia neuvotteluja käytiin parhaan loppuratkaisun saavuttamiseksi, jonka jälkeen uusi koulutuslinja tilattiin. Lopuksi koostettiin yksityiskohtainen implementointisuunnitelma arvioituineen aikatauluineen ja laadittiin toimenpidelista tulevaisuutta varten. Uusi ratkaisu täyttää asetetut tavoitteet ja eliminoi kaikki ongelmat, hukat ja pullonkaulat sekä takaa turvallisuuden, ergonomian, joustavuuden, selkeän virtauksen ja laadukkaan koulutusprosessin. Uuden ratkaisun myötä koulutuksen ja operaatioiden tehokkuus, laatu ja tuottavuus paranevat

Users, Experts, and Institutions in Design

The first act of design was almost certainly user design, in that the plan was created by the user rather than by a third-party designer. Perhaps this first user designer contemplated frustration with a task tens of thousands of years ago, formed a plan to address the frustration, and then fashioned an artifact, possibly shaping a stick of wood into a digging implement. A clear distinction between expert designers and user designers emerged at some point possibly first in the domain of architecture. Certainly by the time ancient Egyptians were creating pyramids, the roles of experts and users in design were separated. This separation was probably motivated by the comparative advantage of experts over users in designing enormous structures. The activity of design appears to have become increasingly professional and institutionalized over the next few thousand years. By the 19th Century, as the industrial revolution developed in full, expert designers with specific technical training assumed distinct professional roles, both because of the comparative advantage of expertise and because institutions were formed to exploit the benefits of mass production

Design of tool management systems for flexible manufacturing systems

The objective of this thesis is to study the design and analysis of tool management system in the automated manufacturing systems. The thesis is focused on two main areas, namely design and experiment. In the first part of the thesis, the design facility created has been reported. The model has been designed using a hybrid approach in which the power of both algorithmic and knowledge based approaches is utilised. Model permits detail, more accurate and complete solutions for the management of tools in a generic manufacturing system. In the second part of the thesis, to add more understanding to the tool management problems, the interactions of the major tool management design parameters have been investigated using a well known design technique, the Taguchi method. For this purpose, a large number of design experiments have been configured where some have been suggested by the Taguchi method and some have been created by the author to add more confidence, using a large body of real industrial data. The experiments results give deeper understanding of TMS problems and allow design guide-lines to be drawn for the designers. The design approach and the experiments have been proven to be an accurate and valid tool for the design of tool management systems for automated manufacturing systems. This is indicated in the conclusion of the thesis

Experience and Innovation Factory: Adaptation of an Experience Factory Model for a Research and Development Laboratory

This paper aims to present a knowledge management proposal for a software factory organization. A software factory requires a holistic organization, in which many factors must be taken into account, such as: people management and business management. The complexity of the structure leads us to elaborate on an adapted model of Experience Factory to meets the needs of research and development laboratories. The construction of the adapted model used a bibliographical research about Experience Factory models, the characterization of the project, a mapping between the project’s characteristics and the activities of the Experience Factory models. The Experience Factory models attend to the main characteristics identified for the Software Factory Laboratory (SFL): development, capacitation, training, research and innovation. Finally, we tested and analyzed the results on the proposed model on the knowledge generated by the SFL during the software development process

Radio hardware virtualization for software-defined wireless networks

Software-Defined Network (SDN) is a promising architecture for next generation Internet. SDN can achieve Network Function Virtualization much more efficiently than conventional architectures by splitting the data and control planes. Though SDN emerged first in wired network, its wireless counterpart Software-Defined Wireless Network (SDWN) also attracted an increasing amount of interest in the recent years. Wireless networks have some distinct characteristics compared to the wired networks due to the wireless channel dynamics. Therefore, network controllers present some extra degrees of freedom, such as taking measurements against interference and noise, or adapting channels according to the radio spectrum occupation. These specific characteristics bring about more challenges to wireless SDNs. Currently, SDWN implementations are mainly using customized firmware, such as OpenWRT, running on an embedded application processor in commercial WiFi chips, and restricted to layers above lower Media Access Control. This limitation comes from the fact that radio hardware usually require specific drivers, which have a proprietary implementation by various chipset vendors. Hence, it is difficult, if not impossible, to achieve virtualization on the radio hardware. However, this status has been changing as Software-Defined Radio (SDR) systems open up the entire radio communication stack to radio hobbyists and researchers. The bridge between SDR and SDN will make it possible to bring the softwarization and virtualization of wireless networks down to the physical layer, which will unlock the full potential of SDWN. This paper investigates the necessity and feasibility of extending the virtualization of wireless networks towards the radio hardware. A SDR architecture is presented for radio hardware virtualization in order to facilitate SDWN design and experimentation. We do believe that by adopting the virtualization-oriented hardware accelerator design presented here, an all-layer end-to-end high performance SDWN can be achieved

User learning, "sticky information," and user-based designs

"May 1995."Includes bibliographical references (p. 34-36).Eric von Hippel