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Development of the electric 600 underbench cavity subassembly build at Electrolux Cooking Plant, Adelaide, Australia
2006 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

This Master’s Thesis was performed at Electrolux Cooking Plant in Dudley Park, Adelaide. Since 2004 a consolidation project called Dudley Park Product Rationalisation Project, (DPPRP), has proceeded at Electrolux Cooking Plant. DPPRP is initiated to reduce costs, increase the efficiency, improve the quality of the products and reduce the number of components. This Master’s Thesis is a part of the DPPRP and was commenced in the phase of introducing the electric 600 underbench oven. The objective of this thesis is to develop efficient and functional solutions for the cavity subassembly build area so that the demand of an annual production of 70,200 ovens can be met. Initially the project was defined within the project group and then the methods were chosen. To get an understanding of the assembly process, the existing electric 600 upswept assembly line was studied as a current situation and a Process Failure Mode Effect Analysis, (PFMEA) was performed. Within the investigation areas layout, material handling, organisation, safety and ergonomics the problem areas were identified. By structuring a theoretical framework the current situation could be analysed. The results of the analysis have formed the basis for finding practicable solutions. By using the Engineered Planning Approach and Simplified Systematic Layout Planning, (SSLP), three conceptual layout proposals were developed. These proposals were compared and evaluated against the specification of requirements to decide which one to develop in detail. The suggested solution for the electric 600 underbench cavity build is a serial production system consisting of three cavity work stations and one insulation work station. The system is flexible to cater for fluctuating production volumes and can meet the production volume demand of 70,200 cavities per year with a line balance efficiency of 96%. The work station design facilitates that the operator performs ergonomically and the storage of components is optimised to be in accordance with the Kanban material handling system. The final layout solution has been evaluated to ensure that it corresponds with the specification of requirements. To make it easy for new employees to learn the assembly process, and prevent failures, work instructions have been developed. A recommendation to Electrolux is to start with using only two cavity work stations during the implementation phase in January when the production volume is 36,800 cavities per year and then add a third cavity work station when the production volume increases.

Place, publisher, year, edition, pages
Keyword [en]
Technology, linjeproduktion, line production, montering, assembly, förenklad systematisk lokalplanläggning, FMEA, produktionsystem, materialhantering, material handling, ergonomi, ergonomics
Keyword [sv]
URN: urn:nbn:se:ltu:diva-54971ISRN: LTU-EX--06/061--SELocal ID: be355b6d-c2db-4cc0-9b5f-cdd64d2ea345OAI: diva2:1028352
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

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