Kartläggning och reducering av produktionsstörningar : En fallstudie av klassificering av stoppkoder samt framtagande av förbättringsförslag till ett producerande företag

Sammanfattning: Production losses and production stops are commonly occurring at production lines and is no value-added activity. To increase the availability in production, reduction of all types of losses and stops are essential to improve the productivity for a producingcompany. The purpose of this thesis was to investigate a selected company’s current machine losses, classify those into stop codes and propose improvements for the production. To understand the current production layout, a pre-study was carried out. The aim was to map the production process and decide suitable activities to use for a frequency study.The goal of the frequency study was to define the existing machine stops and their causes. The results from the frequency study showed that a lot of time was spent on detail errors and fixing those, setup times and the measurement process. Due to many detail errors, new setups was required to ensure that the problem was fixed, which leads to a lot of downtime and reduced availability. After the frequency study, the results and theories were used to develop suitable stop codes that classifies the different machine stops that can occur.The improvement work began with a root cause analysis that was primarily aimed forthe operators and how they experience those problems. During the root cause analysisit was discovered that high percentage of the setup time and the measuring process are spent searching for equipment and tools due to poor structure in the tool cabinets. Alsoqueuing to use a measuring machine.A workshop was then carried out with representatives from operators, technicians, and management. The identified areas from the frequency study were detail errors, set-up time and measurement process. Divided into small groups the participants used an Ishikawa diagram to come up with different causes and proposed improvements foravailability and reduce losses.The proposed improvements and reasons were documented and analyzed, to presentconcrete proposals to clearly optimize and streamline the company's production process, both in short and long term. An example of improvement was to buy thread interpreters for all workbenches as they are often used, this is easy and quick toimplement. Another example was to set higher requirements on the suppliers of materialand tools to always get material from the same factory and tools of the same brand. This to ensure that the quality and specifications variates as little as possible. This providegood conditions for reducing quality defects in production, which in turn increases availability.