Volvo Cars’ assembly instructions evaluation

Abstract

This thesis has investigated the development, implementation, and usage of the assembly instructions within Volvo Cars, focusing on the humans and their behaviors and experiences. The purpose was to reveal, analyze and give recommendations on how to handle issues connected to the instructions. A study including a literature study, interviews, surveys, observations, and an internal document review, was performed. Initially, a theoretical framework was formulated based on the literature study. Data from interviews, surveys, and observations were gathered within a limited part of Volvo Cars. The research questions aimed at revealing the main issues connected to the instructions, and how these issues can be handled. The identified main issues were; communication, culture, and instruction layout and content. The main communication issue was the lack of sharing information, both upstream and downstream. This problem was found both between manufacturing engineers and process technicians, and the production manager and the operators. Further, the culture issue included two main problems; the differing goals and prioritization between manufacturing engineering and the plant, and the shop floor culture allowing for undesired behavior. The final issue is the instruction layout and content, where the main problem is excessive complexity, leading to misunderstandings and incorrect usage. The problem concerning the communication between the manufacturing engineers and the process technicians is likely based on unawareness of the other party’s work. Therefore, it is important to increase understanding. This research indicates that the communication problem within the plant is caused by an undesired culture, partly caused by deficient leadership skills. The culture within the plant leads to undesired behavior such as incorrect usage of the instructions and neglecting of helping tools. This can be handled by developing the leadership structure, which requires further investigation. The issue regarding the differing goals and prioritization between ME and the plant are not reasonable to try to change. Instead, it is important to improve the relationship and adapt to the other party’s work situation. The issue connected to the instruction layout and content can be handled in several ways. The instructions could be simplified, including less information and clearer formulations. Additionally, the need for detailed instructions will decrease if the work station supports the operator and if the training period is sufficient.