Publicação
Improvement and adaptation of a solenoid valve assembly line
| Resumo: | The present master’s thesis was developed in the automotive company Bontaz Portugal, which is inserted in a competitive market, as it is subject to a high number of specific requirements. In order to meet them, it is necessary to innovate, create solutions that will increase the added value and also make its services more efficient. As the enterprise believes that is incurring in additional costs related to operations that do not add value to the product, they have developed improvement proposals that intend to reduce waste in the assembly line, present in Bontaz Morocco. Once the major problems were identified, strategies were created to combat these problems, highlighted in the implementation of Lean strategies, such as 5S and visual management, one-piece flow system and a supply process. In this way, it would be possible to meet customer demand, reduce work in progress, wait for components and promote organization and cleanliness in every workstation. The analysed assembly line is going to produce another reference in 2025 and the company also wants to evaluate the financial interest of the line’s adaptation comparatively to the possibility of creating a new one. A comparative study between the adaptation scenario and the creation of a new assembly line scenario was developed, for the new reference, taking component, tooling, labour, electricity and maintenance’s costs into consideration. After proof that both scenarios could meet customer demand, with the cash flow of each scenario and using indicators of economic viability, it was verified that the adaptation of the assembly line is the best option. The indicators used were the net present value, the internal rate of return and the discounted payback period. The sensitivity analysis presents the increase in sales that would result in the inability to comply with production in 2027 and 2028, with the highest volume of production. |
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| Autores principais: | Rocha, Margarida Martins da |
| Assunto: | Lean production One-piece flow Supply process Economic viability Produção lean Fluxo de uma peça Processo de abastecimento Viabilidade económica |
| Ano: | 2023 |
| País: | Portugal |
| Tipo de documento: | dissertação de mestrado |
| Tipo de acesso: | acesso aberto |
| Instituição associada: | Universidade do Minho |
| Idioma: | inglês |
| Origem: | RepositóriUM - Universidade do Minho |
| Resumo: | The present master’s thesis was developed in the automotive company Bontaz Portugal, which is inserted in a competitive market, as it is subject to a high number of specific requirements. In order to meet them, it is necessary to innovate, create solutions that will increase the added value and also make its services more efficient. As the enterprise believes that is incurring in additional costs related to operations that do not add value to the product, they have developed improvement proposals that intend to reduce waste in the assembly line, present in Bontaz Morocco. Once the major problems were identified, strategies were created to combat these problems, highlighted in the implementation of Lean strategies, such as 5S and visual management, one-piece flow system and a supply process. In this way, it would be possible to meet customer demand, reduce work in progress, wait for components and promote organization and cleanliness in every workstation. The analysed assembly line is going to produce another reference in 2025 and the company also wants to evaluate the financial interest of the line’s adaptation comparatively to the possibility of creating a new one. A comparative study between the adaptation scenario and the creation of a new assembly line scenario was developed, for the new reference, taking component, tooling, labour, electricity and maintenance’s costs into consideration. After proof that both scenarios could meet customer demand, with the cash flow of each scenario and using indicators of economic viability, it was verified that the adaptation of the assembly line is the best option. The indicators used were the net present value, the internal rate of return and the discounted payback period. The sensitivity analysis presents the increase in sales that would result in the inability to comply with production in 2027 and 2028, with the highest volume of production. |
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