Developing Standardized Work in Casting Department : Case Study of Luvata Sweden AB Finspång

Sammanfattning: This thesis is one part of a lean project initiated by Luvata Sweden AB in Finspang casting department. The primary goal of that project is to increase the production efficiency, reduce costs and improve the quality of the copper coil. The aim of this thesis is to develop standardized work in casting department at Luvata Sweden AB Finspang. The research is based on lean thinking and organized in three steps. FIRST STEP: This step implies value stream mapping (VSM) of the current manufacturing process. VSM technique is applied in order to create an overview of the entirety production flow in a casting department, to visualize non-value added activities and to identify process wastes. SECOND STEP: By using lean tools as: Waste Management, SMED and Visual Management, thesis work intends to clean the production process. 7 Wastes or seven forms of Muda were studied at Luvata Finspang. The source of 5 wastes were identified and reduced/eliminated. SMED (single minute exchange of dies) analysis was carried out for a changeover during a casting montage in order to reduce the changeover time and streamline the montage process. Spaghetti diagram was applied particularly to inspect the best location for all montage materials, equipments and tools in a casting floor. Ensuring the efficient implementation of Waste Management and SMED practices Visual Management technique was used. This mean expresses the information about production process, its real-time status and results in a way that could be understood by operators in a shop floor. It is important to clean a production process before the standardized work can be developed, since the purpose of standardized work is to represent the best practice: method and sequence for each process. THIRD STEP: The last thesis step focuses on developing standardized work sheets as a steering tool for operators to follow the best practice while executing their tasks in each work center (melting, casting, rolling) and during the casting montage. The standardized work sheets are designed to show the approved way to perform the specific procedures and are expected to motivate operators to perform theirs job in the common way. That would consequently reduce high variation in operators performance. It would probably take several years before any reasonable improvements could be observed. However the developed standardized work sheets are already placed in the shop floor and successfully used by operators this is my small contribution to a big improvement project!