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Tooteteostusprotsessi optimeerimine Ruukki Products AS näitel

Tohv, Merilyn (2018) Tooteteostusprotsessi optimeerimine Ruukki Products AS näitel. [thesis] [en] Product Process Optimization in Ruukki Products AS.

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Abstract

Tootlikkus ja kvaliteet on organisatsiooni toimivuse üheks põhiliseks edu teguriks. Ettevõtted seisavad silmitsi pidevalt kasvava konkurentsiga ja vajadusega efektiivsemalt töötada. Uuenduste elluviimiseks on oluline, et kogu kollektiiv oleks muutuste rakendumiseks avatud suhtumisega. Lõputöös analüüsiti Ruukki Products AS-i lisaplekkide tootmisprotsessi ja toodi välja põhilised probleemid, mis pikendavad kliendile lubatavat tarneaega. Sellest tulenevalt tehakse ka ettepanekud parendustegevusteks kasutades lean-timmitud tootmise põhimõtteid. Suurim probleem, mis esile kerkis ja mida kinnitasid ka töödejuhatajad, on vajalike tööliste puudumine nii toorikute valmistamisel kui ka kantpressidel töötamiseks. Probleem ilmnes, kuna ribastusliin töötab vaid ühes, kuid kantpressid töötavad samal ajal kahes vahetuses. Ribastusliin toodab kantimiseks vajalikke toorikuid ning vähene toorikute arv sunnib kantpresse tihtipeale lihtsalt seisma. Efektiivse lahendusena pakutakse välja töötajate ristkoolitust. Sellise lähenemise eelis on, et töölised, kes on nõus õppima lisaks oma põhitöökohale veel mõne teise töökeskuse ülesandeid, leitakse ettevõtte siseselt ja seeläbi parendatakse töötajate puudusest tulenevaid probleeme. See võimaldab spetsialistide nappuse olukorras leida huvipooltele sobiva tulemi: kasu nii ettevõttele kui ka töötajaile endile. Organisatsioon ei pea tegema kulusid uute tööliste leidmiseks ja koolitamiseks ning töölised, kes on läbinud ristkoolituse on ettevõttele kasulikumad, sest oskavad tööd teha kahes või enamas töökeskuses ja loovad seeläbi suuremat lisandväärtust. Tööline ise saab uuendusest kasu parema palga näol. Luuakse palga- ja boonussüsteem, mis motiveerib töötama erinevatel kohtadel. Teiseks leiti, et tootmise planeerimine toimub vaid osakonniti ja ei ole süsteemne omavahel seotud töökeskustel. Tööd ribastusliinile planeeritakse seal otseselt klientidele tehtavate tööde järgi ja ei arvestada ettevalmistavad protsesse, konkreetselt toorikute tegemist kantpressidele. Selle lahenduseks pakutakse lõputöös välja CRP-süsteemi kasutusele võtmise. CRP annab ülevaate tootmises toimuvast ja võimaldab kohandada võimsust vastavalt kliendinõudlusele. Süsteem annab märku tootmismahtude muutumisest ja millal tekib vajadus lisatööliste või koguni uue vahetuse järele. Samuti on see hea vahend jälgimaks, kuidas on koormatud üksteisest sõltuvad tootmisosakonnad. Kolmandaks oluliseks probleemiks on ettevõtte kantpresside süsteemse hoolduse ning hooldus- ja remondipäeviku puudumine. Ootamatud rikked põhjustavad seisakuid ja puudub ülevaade seadmete tehnilisest olukorrast. Üheks võimalikuks lahenduseks on koolitada liinioperaatorid seadmeid korras hoidma (protsessi omaniku kaasamine) ja regulaarselt fikseerima seadmete hooldust ja remonti remondi- ja hoolduspäevikuis. Hoolduspäevikusse märgitakse seadmete hetkeolukord ja teostatakse vajadusel hooldus või remont. Selline jälgimine tagab masinate korrasoleku ja pideva valmisoleku tööks.

Abstract [en]

Production companies are facing with constantly increasing price pressures and shorter delivery times. Following the market demand, production and supply needs to be adjusted, inventories must be taken to the minimum to lower the costs and respond to constantly rising prices. The speed and ability to respond to market demand changes is the key to success. The main objective of this thesis product process optimization for Ruukki Products AS was to analyze Ruukki’s press brake department work planning, processes and order types and therefore increase productivity by using the Lean manufacturing tools. The theoretical framework gives an overview of Lean manufacturing history and mentions tools that can be used for identifying and improving the problems in production process. Through interviews with work managers and production manager author identified four major problems in the production process: • lack of qualified staff; • delivery time for customer is too long; • lack of communication between different departments; • maintenance log for press brakes does not exist. To improve the product making process it is necessary to have enough qualified workers for press brakes. Author gives recommendation to train personnel inside of the company. At the moment there are five qualified workers and few assistants for the high season. Assistants are not allowed drive with forklifts or bend the details, they can only help with packing and with easier jobs, which means that they are increasing the costs for the company. It is important to implement cross-training inside of the company. The idea of cross training is to maximize the skills of employees by contracting them by training them so that they can handle multiple machines. This gives the company the opportunity to be more flexible and direct the workforce to the point where it is most needed, making work more efficient. This is especially important at the times where there is not enough work on the route or equipment and the workers are standing. In this case, company can use these people where hands are missing. Ruukki needs to train at least two workers for press brake to cover one shift. For these workers it is necessary to create bonus system that keeps workers motivation up. Secondly, author found that the communication between different work stations is poor and needs improvement. For solving this problem, author recommended system called CRP (Capacity requirements planning). The system will give a signal to work managers when production volumes are growing significantly and there is a need for additional workforce or even a new exchange. It is also a good tool to monitor how much work is done by production departments. With CRP system there is a need to use lean manufacturing tool called heijunka. Heijunka or leveling is the approximation of the quantities produced for a certain period of time, so that production is carried out at a constant pace. This quality tool provides the opportunity to respond faster to customer demand and smooth the bulk of production shortcomings. This method gives opportunity to produce different orders at the same time to save time from setup time and deliver product in shorter period of time which can make Ruukki production process more effective. Thirdly, author found that maintenance log for press brakes does not exist. A well-maintained and well-maintained device also requires smaller repair costs for the company, and provides a sense of security, giving an overview of the work and maintenance of the equipment. Since the Ruukki currently do not have an overview of the situation of the brake press, and the latest faults have been very serious, continuous monitoring of the equipment has to be introduced in the company. The most sensible is to check each and every one of the parts of the press brake every month and fix the problems found immediately. Unexpected faults cause downtime at the most unexpected moment and an overview of the current situation of equipment is lacking.

Item Type: thesis
Advisor: Andres Jagomägi
Subjects: Clothing and Textiles > Quality Management
Economy and Management > Production Management
Divisions: Institute of Circular Economy and Technology > Industrial Technology and Marketing
Depositing User: Merilyn Tohv
Date Deposited: 08 Jun 2018 10:14
Last Modified: 08 Jun 2018 10:14
URI: http://eprints.tktk.ee/id/eprint/3787

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