Change search
ReferencesLink to record
Permanent link

Direct link
Redesign and optimisation of track assembly
2008 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

This Masters Thesis has been performed at Futuris Automotive in Adelaide, Australia. Futuris Automotive designs and manufactures automotive interior solutions. The purpose of this project is to make a recommendation to Futuris Automotive of how the tracks should be assembled at the plant in Edinburgh Park. The track is the steel frame that the front seat cushion rests on and that allows the seat to go back and forth. The aim of the project is to design a Track Assembly area with high labour efficiency, minimum storages and without need of forklifts. The work environment must be safe and ergonomic. The current way of assembling tracks at the plant in Edinburgh Park requires large storages because of the batch building manufacturing principle. This leads to high stockholding costs and long lead times and requires a lot of floor space. The production does not run in a smooth continuos flow because of all the out-of-cycle work that the operators need to do, including running three different sub-assembly stations and change over material racks. The result of the project is that the tracks should be produced in sequence, in the same order that they are used. This solution gives the smallest buffers, shortest lead times and needs no additional equipment. It requires little floor space and allows for good material handling. The weaknesses of the solution, quality and reliability, are handled with quality assurances and a buffer of finished tracks. No forklift is needed, the material is transported with tuggers from the Distribution Centre in sequence. The floor space needed is decreased with 250 square metres compared to the present situation. 1.5 operator less is needed per shift, the stockholding cost is reduced with 22,500 Australian dollars yearly and the lead time through the system is lowered from todays 18-45 hours, depending on track type, to about six hours. A trial of producing tracks in sequence was conducted which did not show any unexpected problems with the solution and we recommend Futuris to do further trials to ensure that the line balancing is reasonable and practical and that the cycle time is matching the takt time before deciding upon implementing it.

Place, publisher, year, edition, pages
Keyword [en]
Keyword [sv]
URN: urn:nbn:se:ltu:diva-51105ISRN: LTU-EX--08/064--SELocal ID: 850ced52-e904-4c09-8897-042c7741d787OAI: diva2:1024468
Subject / course
Student thesis, at least 30 credits
Educational program
Ergonomic Design & Production Engineering, master's level
Validerat; 20101217 (root)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

Open Access in DiVA

fulltext(4285 kB)0 downloads
File information
File name FULLTEXT01.pdfFile size 4285 kBChecksum SHA-512
Type fulltextMimetype application/pdf

Search outside of DiVA

GoogleGoogle Scholar
The number of downloads is the sum of all downloads of full texts. It may include eg previous versions that are now no longer available

ReferencesLink to record
Permanent link

Direct link