This master’s thesis was performed during the fall of 2006 at Cloetta Fazer AB in Ljungsbro. Cloetta Fazer is the market leader in Scandinavia of manufacturing confectionary and chocolates. The purpose of the project has been to identify causes that impact the quantity of waste in production as well as a cost/benefit analysis of the solutions that can reduce the problem of production waste.
The work includes four production lines that are individually designed depending on what kind of product that are produced on the line. By using qualitative and quantitative methods such as focus groups, interviews and observations data has been collected. To fully understand and get good knowledge of the processes was process mapping initially performed. The process mapping illustrated where in the process waste generates and what kind of destination it reaches, i.e. recycling, animal food, the company factory store or deposit. Focus groups with production personnel and salaried employees were created to discuss the types of waste that occurs in production and what it depends on. These causes were categorized and many problems was considered product related but also depending on the operators knowledge of the process. To get information of which of the causes that generate most waste, a production safety analysis has been performed. The method ties the causes to the result by sorting information of causes that leads to waste, stop and loss in production rate. The study has been performed on individual activities and complete processes depending on the information that was received with focus groups. The types of waste that arise are not only that the specific product is incorrect but also related to the process itself such as incorrect placement of the product before next activity on the line.
The solutions that have been developed during the project are mainly related to the process and demand reconstruction or additions to the process. By assessing the sol...
