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Tootmisliini tööprotsessi reorganiseerimine ettevõttes Otto Bock Estonia AS

Teever, Katri (2016) Tootmisliini tööprotsessi reorganiseerimine ettevõttes Otto Bock Estonia AS. [thesis] [en] Reorganizing the Production Line in Otto Bock Estonia AS.

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Abstract

Lõputöö eesmärgiks oli leida lahendusi Otto Bock Estonia AS põlvetoestusmudelitele spetsialiseerunud osakonna töö efektiivsemaks muutmiseks. Lõputöös anti ülevaade Otto Bock Estonia AS tegevusest, ajaloost, ettevõtte struktuurist ning kirjeldati tootmisprotsessi erinevaid etappe. Tootmisliini tegevuse ülevaates toodi välja osakonna asendiplaani kirjeldus, materjalide ladustamiskohad ning õmblusseadmete ning tootmistüüpi iseloomustus, mis oli aluseks parendusettepanekute tegemisel. Müügiprognooside alusel planeeriti osakonda S04 tootmisesse põlve-, sääre- ning küünarnukitoed, millega tagati töö kaheksale õmblejale ning kolmele pakkijale. Mudelite valiku tingimusteks oli sarnane töötlemisaeg, konstruktsiooniline alus, töödeldavad materjalid ning võimalus teostada õmblusi samadel masinatel. Kuna planeerimise käigus sai selgeks, et kõiki tingimusi ei ole võimalik tootmismahu tagamiseks täita, tuli osakonda S04 töösse valida mudel 7953 knee support Basic Line, mille valmistamiseks kasutatakse 1-nõelalist ahelpiste õmblusmasinat, mida ülejäänud tootete valmistamisel ei kasutata. Olukorra lahendamiseks pakuti välja erinevaid võimalusi. Järgnevalt anti ülevaade valitud mudelite õmblemiseks kasutatavatest põhimaterjalidest, detailidest ning tehnoloogilistest järjestustest. Töö efektiivsemaks muutmiseks tuleks masinatejärjestuses ümber paigutatud riiliõmblusmasin ja 4-nõelaline katteõmblusmasin, mis tagaks detailide sujuva liikumise ja järjestikulise edasi andmise. Uue masinate järjestuse koostamisel võeti aluseks sama masinatevahelise liikumisteekonnaga mudelid. Operatsioonide analüüsiks koostati arvutus, kus saadi teada, kui suur on toodete väljalase erinevatel etappidel. Samuti viidi läbi kaks päevavatlust ning tellimuse läbiminekuaja uuring. Operatsiooniaegade tasandamise meetodi valik oleneb pakkijate arvust, kuna määravaks sai toodete väljalaske hulk pakkimisoperatsioonilt. Liinitöö parendamiseks leiti, et paelakastidele tuleks rakendada kanbansüsteem. Uueks kastide asukohaks saaks kattemasinate kõrval olevad kolme lahtriga riiulid. Väljapakutud lahendus tagab pideva materjali olemasolu, likvideerib liigse varu ning väheneb aega, mis kulub õmblejatel kandikastide käsitlemisele ja ette toomisele. Samuti on pakutud välja kaks riiulisüsteemi, mida saaks kasutusele võtta niidirullide hoiustamisel. Uued riiulilahendused tagavad toormaterjalile FIFO meetodi. Viimasena on koostatud kolm parendatud tootmisliini asendiplaani. Esimese asendiplaani saab kasutusele võtta ilma aeganõudvaid muutusi läbiviimata, samas parendaks see tootmiskulgu märgatavalt. Kahe ülejäänud asendiplaanide ellu viimises tuleb teha suuremaid muudatusi, kuna ümber on paigutatud lõpp-pakkimine, kärude parkimisalad ning osaliselt ka osakonna S13 seadmed. Lõputöö autor tunneb, et on täitnud endale püstitatud eesmärgi. Töö autor soovib avaldada tänu ettevõtte poolsele juhendajale Ann Sintonenile, Otto Bock Estonia AS tootmisjuhile Anneli Niitojale ning osakonna S04 meistrile Larisa Chinennayale.

Abstract [en]

The focus of this final paper is on improving and reorganising the specialised sewing line for knee brace models, manufactured by the company Otto Bock Estonia AS, by adopting the use of new solutions to improve the efficiency of production. When it comes to the organisation of production, the company has adhered to the principles of lean thinking in manufacturing, as a result of which constant attempts are being made to find new opportunities on how to improve and supplement the course of operating processes. The same principles have been used in preparing this thesis. An overview is presented first in the thesis on the activities, history and structure of company Otto Bock Estonia AS. In order to understand the activity of the operating line, the various stages of the production process are explained. A more detailed description is given of the organisation of work on the production line, the order of sewing equipment and the type of production, which serves as the basis for reorganisation and making proposals for improvement. In the Chapter titled “Reorganization of the Production Line”, models utilising similar production line materials, the order of processing and the structural basis are selected on the basis of sales forecasts, ensuring work for eight seamstresses. As a result of calculations, it became clear that all conditions could not be met in order to ensure the production volume, and therefore a model had to be planned for the operation of the department in which a 1-needle chain stitch machine would be used for sewing. An overview of the basic materials, details and technological sequences used for sewing selected models is also provided. This is followed by an analysis of the operation of the production line, with knee support product 7751 Rx knee selected as the basis, as it accounts for the biggest share of the production line’s planned products. In order to perform the analysis, calculations were prepared, two machine operators were observed for a day, and a study carried out on the time required for a production order to pass through. A number of different solutions have been proposed on how to smooth out operation times, in order to reduce a surplus of half-complete products from being created between the various stages of sewing. In order to improve the operation of the production line, use of a kanban system should be implemented for ribbon boxes, in order to reduce the storage of raw materials inventory in the production space, save time spent by the seamstress and ensure the continuous presence of materials at the workplace for the machine operator. Also pointed out are two possible storage systems for spools of thread, which best take into account the needs of the department and ensure the handling of raw materials in accordance with the FIFO method. Lastly, three improved layout plans for the production line have been prepared. The first layout can be adopted without the need for performing any time consuming changes, while at the same time notably improving the course of production. Major changes must be made in order to implement the two remaining layout plans, since final packaging and some of the equipment from Department S13 must be rearranged. The plans for the workshop would not only improve the work of the department being reorganised, but also the access of other sewing departments to final packaging, and would give the sewing master of Department S13 a better overview of the work of all machine operators. This thesis is comprised in large part of information gathered during the course of observations, the results of calculations and an analysis of the company’s internal documentation data. Instructional materials, information published on the Internet, as well as Estonian and foreign language literature, were used. In order to better convey the contents, the thesis includes photos, tables and drawings.

Item Type: thesis
Advisor: Ann Sintonen
Co-advisor: Anu Tšistova
Subjects: Clothing and Textiles > Field Studies
Divisions: Faculty of Clothing and Textiles > Clothing Design and Technology
Depositing User: Katri Teever
Date Deposited: 03 Jun 2016 05:32
Last Modified: 03 Jun 2016 05:32
URI: http://eprints.tktk.ee/id/eprint/2349

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