Utilizing Lean Six Sigma to Improve Material Handling Operations in the Production of Heavy- Duty Engines at Volvo Powertrain - A Six Sigma Black Belt Project

Abstract

Volvo Powertrain is facing problems with the current material handling operations in the production site for heavy-duty engines. There are variations leading to ergonomic inefficiencies as well as non-value adding activities, which are leading to negative impacts on productivity. This thesis has been conducted in order to come up with solutions to the current hindrances in material handling for the main engine line as well as provide financial calculations for the benefits of the proposed solutions. The thesis has been structured in order to utilize Lean Six Sigma principles and continuous improvement methodologies as a foundation for problem investigation and analysis, as well as concepts from material handling and ergonomics. The DMAIC (Define-Measure-Analyze- Improve-Control) framework was utilized during this process improvement project. The project aims to provide a future state for an improved material handling process and lead to financial contributions for Volvo Powertrain. The perspective towards problem understanding and investigation has been taken from three diverse standpoints, namely in terms of variation, ergonomic inefficiency and the risk due to physical load on the operators by taking different factors into consideration. Within the DMAIC cycle a pilot project was conducted to compare the performance level of the material handling process from the current state versus that achieved post-solution implementation. The result of this project has essentially led to a more improved performance level within material handling within each of the different standpoints taken for the analysis. Moreover, the findings have also led to financial contributions achieved through a more stable and capable process in the heavy-duty engines main production line. Which could be applied within other production lines as well as industrial environments when applicable.