Framtagande av dynamiskt VSM-verktyg : Ett utvecklingsarbete hos ABB Robotics

Abstract

ABSTRACT Introduction and purpose Development of a VSM tool has been done by performing experimental field work at ABB Robotics, a company that mass produces industrial robots and associated accessories. The tool development, the primary part of the project, mainly puts focus on production aspects. Furthermore, it has been centered on plant layouts of the product layout kind (production line). The purpose of the development is to create a tailored VSM tool that auto generates a foundation for value stream maps based on calculations and possibly simple simulation. The purpose is broken down into two questions where concrete problems can be illustrated: A) How should the VSM tool plainly signal capacity vs. demand, time balances in production and the ratio between value and non-value adding aspects as well as intuitively promote knowledge and in a simple and fast manner be applicable to different kinds of production lines? B) Which constraints are placed on the potential of the VSM tool due to the current situation of the company, how does this contradict the main principles of VSM and how can the company work to maximize the tool´s potential in the future? Methodology and knowledge The development which is characterized by continuous counseling and feedback with the internal mentor is mainly based on laboratory work in Excel. In addition, the work has also involved the making of a user guide as well as an adjustable function for indicating production effects with colors. An evaluation of the tool and the user guide has also been made, which mainly is supported by a test run with the internal mentor and the nature of the methodology. The knowledge that the development uses as its footing mainly involves process- and value stream maps from the company, discussions with company personnel, self-performed laboratory work and theory from Rother and Shooks book “Lära sig se” (2005) and Drew. A. Locher´s book “Value Stream Mapping for Lean Development” (2008). Results The VSM tool manages, in a relevant way, to factor in all aspects that can be interpreted using a typical value stream map. In addition it also provides the following: balances between workstations and production lines, suggestions for amount of WIP between these, simple simulation of WIP between these, disturbance aspects, three total times; manufacturing lead time, inventory time and value adding time as well as a graphic illustration over production courses. The results are considered to fulfill the purpose of the project. Conclusion and future meaning The development results in a hybrid solution of sorts, a tool that exists somewhere in-between the typical draw-by-hand VSM work and simulation software. Its advantage is that it combines VSM theory with intuitive, swift and practical usage, which goes well in hand with today´s fluctuating conditions where time pressure of different kinds are present. The drawback is that the concept as a whole requires complementing in the form of Lean knowledge and gemba observations. Furthermore, there are implications associated with some types of parallel production and editing of the tool, which is to be addressed before implementation. In order to fully utilize the tool, the company also has to examine production times and make a minor adjustment to the process of collecting disturbance data. Three suggestions for the future are given; to study availability, transport aspects and the measuring of production times