Förbättring av Overall Equipment Effectiveness i Bromsskivetillverkning Strategier för effektivare produktionsflöden

Abstract

This thesis was conducted at AC Floby, a company that partly produces brake discs among other components. The study aimed to improve production efficiency on one of their production lines by analyzing the components of the OEE metric: Availability, Performance and Quality. Areas of improvement were identified based on a comprehensive assessment of the potential impact of proposed actions in relation to their feasibility within the company. These trade-offs guided the selection of which aspects of the current state and result that were further discussed. By combining internal data, observations, and interviews with operators, maintenance staff and production engineers, the current state was mapped to help identify areas of improvement. The theoretical framework includes concepts such as Lean Production, Value Stream Mapping (VSM), Total Productive Maintenance (TPM), Value-Driven Maintenance (VDM), as well as models for root cause analysis, data-driven decision-making, and operator engagement. The results indicate that availability is the OEE component with the greatest potential for improvement. Key challenges identified through root cause analysis include poor data quality, lack of standardized downtime registration, long and inconsistent changeover times and recurring technical failures. Additional areas of improvement include the flow of information between departments, the lack of a standardized practice for downtime registration, and insufficient follow-up on preventive maintenance activities. Based on these findings, the main improvement proposals are: measures to enhance data quality, such as more measurement points, standardized downtime registration, and updated cycle times. Furthermore, improvements to buffer dimensioning, development of operator driven maintenance, and application of the SMED methodology are recommended to reduce availability losses on the production line. To ensure the long-term value and feasibility of the proposed improvements, they were also evaluated from the perspective of the four dimensions of sustainability: economic, social, ecological and ethical.