Competitive i Production Systems. KPP202 Fall 2009 / HT09

Transcription

1 Competitive i Production Systems Course Introduction KPP202 Fall 2009 / HT09 Mats Jackson and Anders Hellström School of Innovation Design and Engineering (IDT) School of Innovation, Design and Engineering (IDT) Product and Process Development

2 Objectives The objective with the course is to give a general understanding of the impact of competitive production and logistics within industrial i operations. The course will give an understanding di of modern production and logistics systems as well as discuss the historic development and current challenges for Swedish manufacturing industry. p. 2 School of Innovation, Design and Engineering

3 Learning objectives The student must be able to present her: understanding of production and logistics systems and the effects of outsourcing understanding of TPS Toyota production System knowledge of an historical overview of industrial production systems understanding of competitive and efficient production understanding of the key factors necessary for the follow up of a modern production system understanding di of different future production concepts p. 3 School of Innovation, Design and Engineering

4 Contents, 1/2 1. Historical development from Ford to Toyota - Mass production - Ford - The Japanese evolution Toyota Production System - Sociotechnical production systems - The need for for flexibility and present trends 2. Understanding of production and logistics - What is a production system including logistics - The importance of internal manufacturing? - Reasons for outsourcing - distributed production system p. 4 School of Innovation, Design and Engineering

5 Contents, 2/2 3. Lean production 4. Competitive and efficient production - Important deliverables/ key figures to achieve competitive production systems - Concepts of productivity, quality, delivery capacity, flexibility and availability - Steps towards improved competitiveness, including maintenance for availability - Collaboration between the processes for production and product development - Logistics and materials handling - distributed production p. 5 School of Innovation, Design and Engineering

6 Examination INL2, 4.5 credits, Exercise TEN1, 3 credits, Examination Grade Oral presentation ok or not ok" 3, 4 or 5 on the course - through exam Literature Liker, J, The Toyota Way,,. - ISBN Papers handed out through out the course/ web p. 6 School of Innovation, Design and Engineering

7 Reference to The Toyota Way Basically, every chapter of The Toyota Way is of value to read! Study it individually and preferably also in group discussions. All chapters may occure at the Examination TEN1. Part one gives an introduction to Toyota. If one would point out certain chapters to focus, choose Chapter 1, 3 and 4. Chapter 2 is of historical interest and 5 & 6 are quit interesting case studies. Part two describes the actual 14 principles according to Liker. All chapters should be studied. d It is not possible to point out any chapters/principles more important than others. p. 7 School of Innovation, Design and Engineering

8 Exercise, 1/2 Value stream mapping and analysis of an industrial process a lean technique used to analyze the flow of materials and information currently required to bring a product or service to a consumer A group project 5-6 persons per group, lecturer set-up Need to find your own case within industry or other material handling enterprises p. 8 School of Innovation, Design and Engineering

9 Exercise, 2/2 A report/paper of maximum 10 pages describing; The target product, product family, or service. Drawing of current state value stream map, which is the current steps, delays, and information flows required to deliver the target product or service. This may be a production flow (raw materials to consumer) or a design flow (concept to launch). Waste and disturbance analysis Proposal of a future state value stream map. Implementation plan the future state. Final oral presentation p. 9 School of Innovation, Design and Engineering

10 Lecture ( ) Introduction to the course, Anders Registration Course plan Groups exercise Introduction to the subject and the research group within Product and Process development at Mälardalen University, Mats Lecture From Ford to Toyota part 1, Mats Mass production - FORD Mats Jackson and Anders Hellström p. 10 School of Innovation, Design and Engineering

11 Lecture ( ) 16.00) JIT-game. Just In Time production flow exercise based on push respectively pull approach to show the difference in the resulting flow 15 course members acting as the production staff All participating in observation and analysis Sweeping of the shop floor, all together! Margareta Hammarström PuMHa Production Development, works with consulting within the area of production development. p. 11 School of Innovation, Design and Engineering

12 Lecture ( ) Lecture Value Flow Analysis Method intro, earlier course group results Group Exercise presentation Group task training Planning for Exercise, finding own case in industry or other enterprise Anders Hellström p. 12 School of Innovation, Design and Engineering

13 Lecture ( ) Lecture From Ford to Toyota part 2 a Mass production FORD Toyota Production Systems - Lean Mats Jackson p. 13 School of Innovation, Design and Engineering

14 Lecture ( ) 12 00) Lecture From Ford to Toyota part 2 (cont.) Lecture Sociotechnical Production Systems the Swedish example Lecture The need for flexibility and present trends Mats Jackson p. 14 School of Innovation, Design and Engineering

15 Lecture ( ) Research in Sweden within production and production development Christer Johansson Professor, Jönköping and Chalmers universities, flexible manufacturing Born in Uppsala 1946, Master in Mechanical Engineering 1974, PhD 1982 at Linköping University. After some years at University of Massachusetts in USA and at Linköping University as assistant researcher and professor in teaching he worked among other within the Elektrolux lk l Group. From 1990 to 2000 professor at Linköping iköi University. After that professor at KTH from 2000 and from 2003 professor in flexible production at Jönköping University. p. 15 School of Innovation, Design and Engineering

16 Lecture ( ) 12 00) What is a production systems including logistics What is the value of "own" production The Japanese evolution - quality and lean logistics and materials handling - distributed production Patricia Grah, University of Applied Sciences RheinAhr Campus Remagen Germany, participating in MDH Teaching Staff Mobility program, September She will give references to The Toyota Way and material of further books she use in Germany and to her own work experience. p. 16 School of Innovation, Design and Engineering

17 Lecture ( ) Cont. What is a production systems including logistics What is the value of "own" production The Japanese evolution - quality and lean logistics and materials handling - distributed ib t d production Patricia i Grah, University of Applied Sciences RheinAhr Campus Remagen Germany p. 17 School of Innovation, Design and Engineering

18 Lecture ( ) 12 00) Maintenance introduction. Impact on competitiveness. Antti Salonen PhD student at IDT. Lecturer in the area of maintenance and availability. p. 18 School of Innovation, Design and Engineering

19 Lecture ( ) Total Productive Maintenance Antti Salonen p. 19 School of Innovation, Design and Engineering

20 Lecture ( ) 12 00) Dependability Antti Salonen p. 20 School of Innovation, Design and Engineering

21 Lecture ( ) 12 00) Competitive production systems from Haldex point of view Lean driving at Haldex Monica Bellgran Professor at IDT and Production Manager within Haldex. Haldex is a provider of proprietary and innovative solutions to the global vehicle industry, with focus on products in vehicles that enhance safety, environment and vehicle dynamics. p. 21 School of Innovation, Design and Engineering

22 Lecture ( ) Project presentations, Excercise, INL2, first groups Anders Hellström and teachers at IDT p. 22 School of Innovation, Design and Engineering

23 Lecture ( ) 12 00) Project presentations, Excercise, INL2, last groups Anders Hellström and teachers at IDT p. 23 School of Innovation, Design and Engineering

24 Lecture ( ) Research projects at IDT and their connection to the area of competitive production systems. Course evaluation and feed back. Anders Hellström and doctoral students at IDT p. 24 School of Innovation, Design and Engineering

25 Examination opportunities 1 TEN ( ) Eskilstuna and Västerås 2 TEN ( ) Eskilstuna and Västerås 3 TEN August, if any student still not approved 4 INL2, only possible to examine during scheduled d course at the two days of Presentations, also including documentation at same time! Anders Hellström and Mats Jackson p. 25 School of Innovation, Design and Engineering

26 Participating teachers in KPP202 Fall 2009 Monica Bellgran (PhD). Works as Director of Production Technology and Systems at Haldex AB since Adj. Professor in Innovative Production Development at MDH since Bellgran Patricia Grah. University of Applied Sciences RheinAhr Campus Remagen Germany, participating in MDH Teaching Staff Mobility program, September Her area of research is "innovation and competence management". At her University she is leader of the Quality Management workgroup Communication and its Structures. She has own practice experience from large enterprises such as General Motors and the international part of the German Post. She has great interest in international marketing. p. 26 University of Applied Sciences RheinAhrCampus Remagen Germany /Fachhochschule Koblenz Fachbereich Betriebs- und Sozialwirtschaft Südallee 2D Remagen Tel.: +49 (0) 2642 / Fax.: +49 (0) 2642 / grah@rheinahrcampus.de School of Innovation, Design and Engineering

27 Margareta Hammarström. PuMHa Production Development. Works with consulting within the area of production development. Västersjövägen 59, Surahammar Mobil References among others: AB Volvo Köpingsverken, ABB AB, ABB Adda Italy, ABB Automation Products, ABB Cewe, ABB Control, ABB Corporate Research, ABB HV Switchgear in Sweden and italy, ABB Industrial System, ABB Managemanet Consultants, ABB Medium Voltage Switchgear, ABB Motors, ABB Power Plant Production, ABB Power System, ABB Production Development, ABB Signal, ABB Transportation Management Germany, BOC Ohmeda, Flextronics International, Gränges Foral, MälarEnergi, Nutek, Storm Enterprises, Travel design Anders Hellström, MSc in Electronic Engineering at Linköping University. Works as Head of Production, Design and Logistics division. Lecturer in product development and quality assurance at MDH since Engineering and management experience from industrial product development and production of safety, automotive and cash handling systems. Hellstr%F6m p. 27 School of Innovation, Design and Engineering

28 Mats Jackson (PhD) is a professor in Innovative production at the School of Innovation, Design and Engineering at Mälardalen University. He is responsible for the research group within product- and process development. He received his PhD degrees from Linköping University, Sweden. His research interests are flexible and reconfigurable production systems. He is project leader of the Swedish national research project Factory-in-a-Box. ckson Christer Johansson (PhD) works at School of Innovation, Design and Engineering at Mälardalen University since January 2009, he is a Professor in Production Systems at Jönköping University. He received his PhD degrees in 1982 at Linköping University. His research has during the last fifteen years been focused on development of manufacturing systems. The research has been concentrated on principles, methods, and tools for design, development, and evaluation of flexible manufacturing. Johansson p. 28 School of Innovation, Design and Engineering

29 Antti Salonen is a PhD student in Product and process development. His scope of research is Maintenance strategies in the manufacturing industry. onen p. 29 School of Innovation, Design and Engineering

30 Course homepage kpp202, continuously updated: p. 30 School of Innovation, Design and Engineering

31 Group start up Le 1 Individually ypresent to the group: 1. What do I want out of these course: 2. What gives me extra energy, how to get the best out of cooperating with me: 3. I want you, other members of the group, to remember me from this working together as the one that: For the group (group leader direct the descussion): When and were can we meet for our first group meetings for the nearest weeks. Make a communication list! Short discussion from groups at Le 3 from this. p. 31 School of Innovation, Design and Engineering