Produktionssimulering av komponenttillverkning: En simuleringsstudie av kamringstillverkningen hos Bosch Rexroth Mellansel
Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
The purpose of this project was to create a better understanding of the cam ring production and provide information on how to reduce customer order lead time. The method used was discrete event simulation. A model of the cam ring production was created in ExtendSim 8 and experiments were performed. Bosch Rexroth Mellansel manufactures durable hydraulic radial piston motors. The motors come in five models that are called CA, CB, CBM, VI and MA. For each motor there are one to six cam rings depending on the model, and there are a total of 30 types of cam rings. The production system consists of four main processes: Milling, hardening, grinding and quality control. The material flow and production control is quite complex which creates frequently occurring problems. One of the main contributors to the complex system is the hardening work cell called EFD, due to a first piece destructive testing and long setup times, large batch sizes are being used. The scope of the simulation was the production of cam rings, from raw material to completed components ready for assembly. The simulation time was 315 days and each experiments was conducted with 3-10 simulation runs. The results from the simulation studies are: •Big batch sizes create long lead times and irregular machine load. •The production can successfully be controlled by using a reorder point. •The planned inventory levels in the MRP (Manufacturing Requirements Planning) system Axapta can be better adapted to fit the demand. •Destructive testing motivates large stocks, large batch sizes and creates test costs of approximately (DELETED) million SEK each year. •An investment of nondestructive testing is estimated to give an approximate payback time of 1,4 years. When implemented, there is a potential to reduce batch sizes by half from current sizes, which would increase flexibility. It would also reduce tied up capital by (DELETED) million SEK. These recommendations were made to Bosch Rexroth Mellansel: •Invest more resources for evaluating the applicability of nondestructive testing and to implement it if possible. •When nondestructive testing is implemented and set-up time in the EFD machine is reduced, reduce batch sizes step by step to find appropriate levels. •Create a standardized production control which has its roots in the master production schedule. •Adapt the planned inventory and the batch sizes in Axapta to fit the appropriate levels.
Place, publisher, year, edition, pages
2013. , 78 p.
Teknik, Simulering, extend, extendsim, diskret händelsestyrd simulering, produktionssimulering, Bosch Rexroth, Bosch
IdentifiersURN: urn:nbn:se:ltu:diva-55452Local ID: c4ff01cf-d0ca-4f15-a635-12cffc8ab512OAI: oai:DiVA.org:ltu-55452DiVA: diva2:1028834
Subject / course
Student thesis, at least 30 credits
Industrial Design Engineering, master's level
Validerat; 20130702 (global_studentproject_submitter)2016-10-042016-10-04Bibliographically approved