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.
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