Maximizing productivity in paint industry: Using lean philosophy and virtual simulation

Abstract

The purpose of this thesis was to assess the productivity of Hydrodip AB in the paint industry and determine how discrete event simulation in conjunction with lean production could be used to make improvements. In the future, the case company hopes to have lean production and discrete event simulation (DES) as a standard approach to all their manufacturing. The scope of the project included determining the current productivity, identifying current wastes, and identifying improvements to increase the productivity. The question answered in this project was how productivity can be improved through lean production and simulation in the painting industry. The selected method to perform the project included on-site observations, interviews and data collection to conduct a current state value stream map (VSM). The future state map was then developed using lean philosophy to reduce the wastes identified, in conjunction, DES was used to verify the improvements from the future state VSM. The report uses traditional methods used in all types of manufacturing such as the automotive one and implements it in a job-shop paint industry. This report could thus be used as a template for paint companies that are looking for an approach to increase productivity, using the thesis as a guide to a new area to explore with lean production and simulations. The authors chose the simulation program Tecnomatix plant simulation for their project because they have previously worked with it. The software is complicated, making it possible to design and visualize any production system. Nevertheless, it takes time to implement all the elements necessary for the system to accurately depict reality. It was determined that without any investments for the case company, it is possible to reduce the production lead time with 46% or 26 hours by implementing improvements produced in the future state VSM. It was further discovered that investing in a new heat lamp, a different primer and an additional grinding room could decrease the production lead time with 87%. This will contribute to an efficient and profit-driven production if implemented. Due to limitations such as time and budget constraints, the authors will not see the implementation of the recommended improvements produced by their work at Hydrodip AB.