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Volvo Technology Chalmers University of Technology. Master thesis project. Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry. Xiaoxia Chen Production System

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master thesis project

Volvo TechnologyChalmers University of Technology

Masterthesis project

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

Xiaoxia Chen Production System

Xiaojin Qiu Management and Economics of Innovation

slide2

Volvo TechnologyChalmers University of Technology

Xiaoxia Chen

Xiaojin Qiu

I am looking for a job now, if you need asmartanddiligentemployee in LEAN, welcome to contact:

chnxiaoxia@yahoo.com.cn

Trainee at SKF, China operation.

agenda

Volvo Technology Chalmers University of Technology

Agenda
  • Introduction
  • Generation and implementation of evaluation method
  • Conclusion
  • Limitation
  • Discussion

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

introduction

Volvo TechnologyChalmers University of Technology

Introduction

- Background (lean & environment)

- Aim (Research questions )

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

research methodology and tools

Volvo TechnologyChalmers University of Technology

Research Methodology and Tools
  • Interview
  • Literature review
  • Case study:

- Study visit (video, pictures)

- Survey

- Observation

- Avix (time study), Spaghetti diagram (MH analysis) and so on

  • Focus group discussions

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

slide6

Volvo Technology Chalmers University of Technology

Research Methodology and Tools

  • Interview
slide7

Volvo Technology Chalmers University of Technology

Research Methodology and Tools

  • Literature review
generation of evaluation method

Volvo Technology Chalmers University of Technology

Generation of Evaluation Method
environmental impacts

Volvo Technology Chalmers University of Technology

Environmental impacts
  • KPI – Key Performance Indicator
  • How are KPIs selected in Volvo
    • Group and plant level
  • How KPIs are selected in the evaluation method :

- Depends on process

- Focus on input and output

Life Cycle thinking

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

evaluation method

Volvo TechnologyChalmers University of Technology

Evaluation method

Step 1: Boundary definition

Step 2: Measure the production performance and Environmental impacts both before and after lean implementation in VSM

Step 3: Visualize the Environment performance by using Loss model

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

evaluation method1
Evaluation method

Volvo TechnologyChalmers University of Technology

Step 1. Boundary definition

Case study illustration

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

evaluation method2

Volvo TechnologyChalmers University of Technology

Evaluation method

Step 2: Measure the production performance and Environmental impacts both before and after lean implementation in VSM

Case study illustration

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

slide15

Volvo Technology Chalmers University of Technology

Current state

slide16

Volvo TechnologyChalmers University of Technology

Current state analysis

  • Avix analysis
  • Material handling analysis
  • Item category
  • Replenishment strategy
  • Price
  • Size
  • Suppliers
slide17

Volvo TechnologyChalmers University of Technology

Avix (time study)

Task and operations for the

bracket 1 assembly for D6 in station 300.

Result for station 300

Activity analyses for one of the operation

slide18

Volvo TechnologyChalmers University of Technology

Material handling analysis (Spaghetti diagram)

slide19

Volvo TechnologyChalmers University of Technology

Lean implementation

Suggestion 1: Get rid of the wood pallets

Non-investment solution: Replace with gray box

suggestion 2 add containers on carrier commons used items

Volvo TechnologyChalmers University of Technology

Suggestion 2: Add containers on carrier (commons used items)

Engine illustration

Consoles

Added containers

slide21

Volvo TechnologyChalmers University of Technology

Suggestion 3

Move the gasket to the turbo cart

(Sequence together)

slide22

Volvo TechnologyChalmers University of Technology

Suggestion 4: Move the plastic waste bin to the cart

slide26

Volvo TechnologyChalmers University of Technology

Results from improvements

  • Production efficiency (11 8 min.)
  • Station size
  • Movements frequency
  • Feeding frequency
slide29

Volvo TechnologyChalmers University of Technology

Movements frequency (Spaghetti diagram)

The spaghetti diagram of

the operator’s movement

(current state)

The spaghetti diagram of

the operator’s movement

(future state)

evaluation method3

Volvo TechnologyChalmers University of Technology

Time

Valued operating time

Losses

Valued operating time

Internal handling & transportation time

External transportation time

Administration

Time in storage

Others

Necessary environmental impacts

ELU

Losses

Energy

Material

Transportation

Chemicals

Others

Evaluation method
  • Step 3: Visualize the Environment performance by using Loss model

Case study illustration

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

loss model

Volvo TechnologyChalmers University of Technology

Loss model
  • Loss definition
  • Define loss category

Loss is “anything other than the minimum amount of equipment,

materials, parts, space, and worker’s time which are absolutely

necessary to add value to the product.”

- Shoichiro Toyoda, President, Toyota

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

loss model1
Loss model

Volvo TechnologyChalmers University of Technology

Loss is “anything other than the minimum amount of equipment,

materials, parts, space, and worker’s time which are absolutely

necessary to add value to the product.”

- Shoichiro Toyoda, President, Toyota

Loss definition

Define loss category

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

loss model production perspective
Loss model -Production perspective:

Volvo TechnologyChalmers University of Technology

Divided by categories:

Overview:

loss model production perspective1
Loss model -Production perspective:

Volvo TechnologyChalmers University of Technology

Divided by categories:

Overview:

slide37

Volvo TechnologyChalmers University of Technology

Loss model -Environment perspective:

Divided by categories:

Overview:

slide38

Volvo TechnologyChalmers University of Technology

Loss model - Comparison

Production:

Environment:

conclusion

Volvo TechnologyChalmers University of Technology

Conclusion
  • Answers to the research questions

1. Lean implementation

Benefit?

Environment

Overall:

2. Visualize the Environment performance:

YES!

VSM & Loss Model

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

limitation
Limitation

Volvo Technology Chalmers University of Technology

  • Research limitations
    • Lean Environment
    • Lean implementation in production Environment

NOT lean Environment

  • Information limitations

- Interviewees: access and knowledge

- Literature review

  • Time limitations
    • No time to see the future state

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

discussion

Volvo TechnologyChalmers University of Technology

Discussion
  • Applicability in other processes

Machining?

Assembly

Painting? Or

Other processes?

Also Applicable

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

discussion1

Volvo TechnologyChalmers University of Technology

Discussion
  • Difficulties

- The implementation of MH – VSM

To sum up different item flows into one flow

- Loss model modification (definition of categories)

The definitions of categories both in production and environment

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

discussion2

Volvo TechnologyChalmers University of Technology

Discussion

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry

discussion3

Volvo TechnologyChalmers University of Technology

Discussion
  • Future study

- More case studies to verify the evaluation method

- Continuous improvement

- Implement lean concept into environmental care

(make use of the relationship between lean and environment )

Evaluate the Environmental Impacts of Implementing Lean in the Production Process of Manufacturing Industry