Three different manufacturing lines are chosen to be investigated and different solutions are suggested which are all beneficial for the company. All three lines are considered from the Lean manufacturing point of view. The most common failures in the factory are caused by the system called Poka-Yoke. The three chosen line are being investigated from this aspect of view as well and different solutions are given in this project. The existing systems at these lines are compared to the FPS, which finds its roots back in Lean Production. The FPS is described in this project in a specific chapter. The readers can also find the history behind the FPS and Lean production and the comparison between the FPS and Toyota Production System in this project. The authors have also gone through different construction arrangement by the side of these three lines and have come up with some solutions from the Lean manufacturing point…
Contents
1. Introduction
1.1 Background
1.2 Problem Formulation
1.3 Aim
1.4 Research Issues and Delimitations
1.4.1 Research Issues
1.4.2 Delimitation
2. Theoretical Frame of Reference
2.1 Overall Quality Theory
2.1.1 Definitions
2.1.2 Success and Quality
2.1.3 Quality and Productivity
2.1.4 Total Quality Management (TQM)
2.2 Human Reliability
2.2.1 Different Analysis of Human Reliability
2.3. Main References of Frame
2.3.1 Lean Production
2.3.1.1 A Brief History of Lean
2.3.1.2 Lean Production Definition
2.3.1.3 Principles of Lean
2.3.1.4 The 7 Wastes (Harrison & Hoek 2005)
2.3.1.5 Lean Product Design
2.3.1.6 Lean Facility Design
2.3.1.7 Two Relevant Aspects of Lean
2.3.2 Ford Production System (FPS)
2.3.2.1 A brief History of FPS
2.3.2.2 FPS Definition
2.3.2.3 FPS Gearwheel Concept
2.3.2.4 FPS Vision
2.3.2.5 Key Principles
2.3.2.6 Plant Operation System Implementation
3. Method
3.1 Research Methods
3.1.1 Research phase
3.1.2 Inductive
3.1.3 Deductive
3.2 Work form and Arrangement
3.2.1 Qualitative and quantitative investigation
3.3 Reliability
3.3.1 Validity
3.3.2 Reliability
3.4 Information Gathering
3.4.1 Primary Data
3.4.1.1 Interview
3.4.1.2. Meeting
3.5 Method Criticism
3.6 Structure
4. Volvo Cars Torslanda/Empiric
4.1 Company Overview
4.1.1 Company philosophy
4.2 Company Background
4.2.1 Markets and Sales
4.2.2 Production
4.2.4 Design
The Scandinavian heritage
Global design process
4.2.5 Product Development
4.3 Manufacturing Overview
4.3.1 Identification of Automotive
4.3.1.1 Identity
4.3.1.2 Labelling
4.3.1.3 Variants
4.3.1.4 Cameras
4.3.2 Superior Production Governing Systems
4.4 Investigation
4.4.1 Poka-Yoke
4.4.1.1 Poka-Yoke Structure
4.4.1.2 Cost Example
4.4.2 Lines in Focus (Poka-Yoke point of view)
4.4.2.1 Door Lines
4.4.2.2 Battery Line
4.4.2.3 Line 1:07 the Safety Triangle Station
5. Analysis and Discussion
5.1 Lean/FPS Analysis and discussion
5.1.1 Lean/FPS Aspect on the Door Lines
5.1.2 Lean/FPS Aspect on the Battery Line
5.2 Problem Analysis and Recommendation
5.2.1 Door Lines
5.2.1.1 Problem Analysis
5.2.1.2 Recommendation
5.2.2 Battery Line
5.2.3 Safety Triangles Line 1:07
6. Conclusion
References
Author: Latifi, Madeleine – Sahar,Latifi, Setareh – Stella
Source: University of Boras
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