Increased capacity through load chart scheduling based on standardization of long-cycle manual work

Abstract

This master’s thesis project has been carried out at the AkzoNobel International Paint factory in Angered, Sweden. The purpose of this thesis has been to increase the capacity at the factory’s P3 pan charging department and to improve the weekly charging schedule by calculating ideal lead times for the most frequently produced products. Due to the large product range (around 130 different products), product lead times were not measured from start to end. Instead all possible work tasks used to manufacture the different products were identified in order to set a standard time for each work task. The work tasks were then combined into a sequence using the unique work order for each product. The work tasks and their sequences were created in the software AviX, which summarized the standard times for all work tasks into complete lead times for each product. Each work task’s standard time was established either by direct time study measurements, usage of the SAM predetermined time system in AviX or a combination of the two. Most of the data collection for the work tasks was done using a video camera. In total 70 product lead times were created in AviX, which historically covers 93.4 percent of the production in the P3 pan charging department. Each lead time was visualized by a so-called scheduling bar divided into different colors, which represented different types of times, such as machine times and time for manual work. These scheduling bars were then used in a new load chart scheduling system created in Microsoft Visio. The result indicates that using this scheduling system could on average give an increased capacity of more than 120 percent. The capacity increase can be used to assure that the weekly volume demand is always met. It will also free up time to work with continuous improvements and 5S as well as time for training of the charging personnel.