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Optimization of the Cab Production Sequence: A simulation-based study at Volvo Group Trucks' cab plant in Umeå
Umeå University, Faculty of Science and Technology, Department of Mathematics and Mathematical Statistics.
Umeå University, Faculty of Science and Technology, Department of Mathematics and Mathematical Statistics.
2016 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesisAlternative title
Optimering av produktionssekvensen : En simuleringsbaserad studie vid Volvokoncernens hyttfabrik i Umeå (Swedish)
Abstract [en]

Volvo Group’s cab plant in Umeå produces cab bodies and consists of three operating areas; the Stamping and parts production, the Body in White and the Paint shop. Today the plant produces around XXX cabs/week, but the goal is to reach the invested capacity of XXX cabs/week. In order to increase the production capacity, the efficiency of both the manual and the automated processes need to be improved. Unlike the manual processes in where the capacity can be increased by enlarged workforce, the automated processes need to be optimized.

Today the cabs are produced in the same order as the orders are received. The cab plant wants to investigate if the capacity of the automated segment in the Body in White unit can be increased by changing the order in the production sequence. This culminates in the following problem definition:

 Is there untapped potential of the Body in White that can be achieved by an optimization of the production sequence? If so, how can Volvo Group’s cab plant in Umeå utilize this knowledge in the production planning process?

The objective of the project was achieved by combining discrete event simulation with a heuristic optimization approach. The results shows that long batches in the production sequence limit the throughput of the system. By spreading the unfavorable subsequences of batches evenly over the production sequence, the total throughput of the Body in White can be increased by 52 cabs/week.

Abstract [sv]

Volvokoncernens hyttfabrik i Umeå producerar förarhytter och är uppdelad i tre driftsområden; pressning och detaljtillverkning, hyttsammansättning och ytbehandling. Idag producerar fabriken ca XXX hytter/vecka, men möjlighet finns att nå upp till den investerade kapaciteten på XXX hytter/vecka. För att kunna öka produktionskapaciteten behöver både de manuella och de automatiserade processerna effektiviseras. Till skillnad från de manuella processerna, där kapaciteten kan ökas genom att öka antalet operatörer, behöver de automatiserade processerna optimeras.

Idag produceras hytterna i samma ordning som beställningarna kommer in. Hyttfabriken vill undersöka om det finns en möjlighet att öka kapaciteten för den automatiserade processen i Body in White genom att optimera produktionssekvensen. Detta leder fram till följande problemformulering:

Finns det outnyttjad potential i Body in White som kan uppnås genom att optimera produktionssekvensen? Hur kan Volvokoncernens hyttfabrik i Umeå utnyttja denna kunskap vid planering av produktionen?

Målet med projektet har uppnåtts genom att kombinera diskret händelsesimulering med optimering genom heuristiker. Resultatet visar att stora batcher av samma variant i produktionen begränsar genomströmningen i processen. Genom att bland annat sprida ut de ogynnsamma delsekvenserna jämnt över produktionssekvensen kan den totala genomströmningen i Body in White ökas med 52 hytter/vecka. 

Place, publisher, year, edition, pages
2016. , 33 p.
Keyword [en]
production sequence, sequencing, simulation, heuristics
National Category
URN: urn:nbn:se:umu:diva-123343OAI: diva2:945445
External cooperation
Volvo Group Trucks
Educational program
Master of Science in Engineering and Management
Available from: 2016-07-06 Created: 2016-07-01 Last updated: 2016-07-06Bibliographically approved

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