Vase puuduse probleemi uurimine mähiste tootmises, ettevõttes ABB AS, Jüri M&G tehases

Kuznetsov, Juri (2020) Vase puuduse probleemi uurimine mähiste tootmises, ettevõttes ABB AS, Jüri M&G tehases. [thesis] [en] Investigation of the Problem of Copper Deficiency in the Coil Manufacturing Dept at ABB AS, Jüri M&G Factory.

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Abstract

Oma töös autor vaatles probleemi, millega ta puutus kokku tööülesannete täitmise ajal. Töö alguses autor kaldus hüpoteesile, et tegemist on kompleksse probleemiga, mis on esiteks seotud inimeste rolliga tööprotsessis: sellega, kuidas töötaja töödokumentatsiooni ja protsesse aru saab, ja teiseks puutub kokku ka seadmete pargiga: seadmete omadustega, nõrkustega, erisustega. Sellise kompleksse teema uurimine nõudis mitu kuud aega ja tasus end ära, kinnitades autori algset hüpoteesi. Juhtumiuuring toimus 2019 a. detsembrist 2020 a. aprilli keskpaigani, selle aja jooksul kontrollis autor probleemi olemasolu, kogudes andmeid materjali erakorralisest ostmisest. Meeskonna uurimisel viis autor läbi intervjuusid töötajatega ning korraldas ka nende anonüümset testimist. Autor kontrollis järjepidevalt ka ABB tehases kasutatud regulatiivseid ja töödokumente, kontrollides nende vastavust ABB-s kehtivatele kvaliteedistandarditele, samuti uuris autor standardprotsesse. Eraldi uuris autor seadmepargi seisu, vaatluse ja intervjueerimise teel. Kuna autor töötab ABB M&G tehases töödejuhatajana, tal oli võimalus vestelda ka remondiüksuse mehaanikutega. See aitas kaasa parandusmeetmete valimisele ning meetmete efektiivsuse hindamisele. Uuringu tulemusi kogudes ja neid analüüsides jõudis autor järeldusele, et probleem on tõesti mitmetahuline ja selle juur peitub personali tegevustes, ebatäiuslikes seadmetes, tõhusa motivatsioonisüsteemi puuduses, aga ka paljudes teistes keeltes kasutatavate tüüpdokumentide kättesaamatuses, eriti arvestades töötajate rahvusvahelist koosseisu. Kompleksne probleem nõuab terviklikku lahendust. Autor usub, et kerimispinkide operaatorite jaoks tuleks luua motivatsioonisüsteem, mis hõlmab nii rahalisi kui ka mitterahalisi aspekte. Autor soovitab korraldada operaatoritele kvaliteediga seotud praktilisi koolitusi, analüüsides aktiivselt olukordi, mille jooksul on operaatoritel võimalus vaadata oma töö tulemusi tootmisprotsessi teisel pool. Seadmete park on koosneb **% vananenud masinatest. Vananenud varustust tuleb hoida heas tehnilises seisukorras, samuti varustada olemasolevad seadmed poka-yoke süsteemidega. Autor arvab, et sellised täiendused ei vaja suuri finantsinvesteeringuid ega keerukat projekteerimist, aga lahendavad enamik seadmete pargiga seotud praagijuhtumitest. Kuna tehasel on rahvusvaheline meeskond ja paljud selle esindajad saabusid teistest riikidest, tuleks kogu tehniline ja üldine dokumentatsioon tõlkida lisaks inglise ja vene keelde. Kuna tehase tooted on täpsete tehniliste arvutuste tulemus ja nõuavad standardsete protseduuride järgimist, peab iga töötaja dokumentidest täielikult aru saama, mitte aga osaliselt. Üldiselt ei nõua probleemi lahendamine suuri investeeringuid, kuid see võib tehasele anda märgatavat kasu materjalikulude vähendamise, meeskonna töötingimuste parandamise, tarnekindluse parandamise ja klienti maine kasvu näol. Autor arvab, et probleemi parim lahendus on probleemi ennetamine. Generaatormähise kvaliteet algab kerimispingist. Kerimispingi operaator on võimeline probleemi nii ennetada kui ka ignoreerida, tema on see isik, kes ei lase vigastatud traadi edasi tootmisesse, tema on ka see, kes paneb põrandale kukkunud mähisetooriku pooltoodangu kärule. Tema tegevustes on probleemi lahendamise võti. Uuendatud „vana“ kerimispink aitab probleemi ennetada või signaliseerib probleemi olemasolust. Operaator on see inimene, kes reageerib kas õieti või valesti. Head operaatorit tuleb kasvatada, õpetada ja juhendada. Lähitulevikus autor kavatseb käesolevas töös toodud meetodid ellu viia.

Abstract [en]

The author had studied the problem in its complexity, collecting and comparing the data and information, studying the documentation, observing the team and their workplaces. The hypothesis that the root of the problem is hidden in many factors, is found to be true, and corresponds with the factors, claimed in the Ishikawa diagram. All four components – people, processes, documents, and equipment – are involved in the creation of the problem, but their influence is not equal. The case study took place from December 2019 until mid-April of 2020, during which time the author checked for the existence of the problem by collecting data on the urgent extra purchases of the material. During the research on the operators’ team, the author conducted interviews with the employees and arranged their anonymous testing. The author also thoroughly checked the regulatory and working documents used at the ABB factory, checking their compliance with the quality standards of ABB, and examined the standard processes. The author researched the condition of the equipment park by observing and interviewing. As the author works at ABB M&G factory as a foreman, he also had the opportunity to talk to the mechanics of the repair unit. This helped to select the corrective actions and to evaluate their effectiveness. Analyzing the collected information, the author has defined the operator to be the main root of the problem. The other mentioned components simply increase the possibility of the error to appear. The author does not want to let this answer be misleading – the operator’s wrong decisions are often becoming a response to the weaknesses found in other parts of the production: in machinery, in process and documentation. Some documents are available only in Estonian language, despite the multinational nature of the factory personnel, the units of machinery are mostly obsolete and are lacking the mechanisms of automated quality control. But the root cause of the problem is in the actions of the operator. He is the one, who stops the production if facing the flawed material, and he is the person, who loads the damaged coil blank to the trolley with coils, prepared for the next stage of production. In the first case he acts as a professional and a responsible person, in the second case the piecework motivates him to carry on without a doubt, hoping, that nothing bad will happen. A complex problem requires a comprehensive solution. The author believes that first, a motivational system should be created for looping operators, covering both financial and non-financial aspects. The next step should be learning to produce goods with built-in quality. The author recommends organizing practical quality training for operators, where they can actively participate in analyzing situations, in which they can see the results of their work from the other perspective, from the other side of the production process, to witness the consequences of the fault actions, seeing the results of their missteps and wastes. The best way to solve the problem is to prevent it from happening. This includes the documentation, translated in Russian and English, so any member of the team can understand the procedural steps and quality aspects not in general, but to its last letter or number. The additional information on quality is also a must. The state of the equipment park should be supervised, and some minor poka-yoke modifications are needed to be done. The complex problem should be dealt complexly. But the main role is in the hands of the operator. He will prevent, if he is taught to, if he is motivated and sees the whole picture, he will react. One of the ABB’s mottos is “The best team delivers the best value”. The best team will not appear out of nowhere. The best team should be fostered, it is a result of constant work and care, and it consists of the people. The people, which are best trained, equipped, and motivated. The author will strive to bring the measures of solving of the problem to life in the nearest future.

Item Type: thesis
Advisor: Ruslan Raid
Subjects: Working Life > Data and Word Processing
Working Life > Quality Studies
Working Life > Project Management and Document Processing
Divisions: Institute of Technology and Circular Economy > Production and Production Management
Depositing User: Juri Kuznetsov
Date Deposited: 04 Jun 2020 11:25
Last Modified: 04 Jun 2020 11:25
URI: https://eprints.tktk.ee/id/eprint/5246

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