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Quality Assurance in Low-Volume Assembly Line at Scania

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Quality Assurance in Low-Volume Assembly Line at Scania Quality assurance in low-volume assembly line at Scania Erik Aasa Kitiphum Noosalung Mechanical Engineering, master's level 2020 Luleå University of Technology Department of Engineering Sciences and Mathematics E7012T MASTER OF SCIENCE MECHANICAL ENGINEERING, PRODUCTION Quality assurance in low-volume assembly line at Scania Erik Aasa Kitiphum Noosalung Division of Product and Production Development Department of Engineering Sciences and Mathematics January 20, 2020 Acknowledgement During these months we have been working with this master thesis, corresponding to 30 credits, which is our final project. First and foremost in order to perform this thesis, we would like to express our gratitude towards Scania CV AB and the initiator of the project Christer Wilhelmsson for the opportunity. Secondly, we have been supported by two supervisors during this period; Linda Br¨ann¨asKus´en(Scania) and Jesper Sundqvist (LTU). Thank you for all your help, by answering our questions, supported us and pro- vided guidance on how to move on during the entire project. In additional, a special thanks to the DTTGP department of Product Introduction and E-mobility Projects, everyone we met during our study visits for your collaboration, effort, time, inspiration and also for the period enriched with experience. Last but not least, we would like to thank our families and friends for the support, belief and encour- agement throughout all these years. Thank you all, we really do appreciate it! .......................................... Erik Aasa, S¨odert¨alje January 20, 2020 .......................................... Kitiphum Noosalung, S¨odert¨alje January 20, 2020 Abstract Scania are now going through a transformation process from being a supplier of trucks, busses and engines to a supplier of complete and sustainable transport solutions. Scania's transmission assembly department in S¨odert¨aljeis facing a variation of changing challenges linked to the powertrain and customer of tomorrow. Some of the challenges is related to assuring quality on low-volume electrified and hybridised products. In this thesis quality assurance of a low-volume assembly line at transmission's department has been investigated. The aims for the thesis project are to evaluate today's methods, equipment and process descriptions for how quality assurance are handled and how it can be implemented in a low-volume assembly line. The aim is to investigate what kind of quality assurance methods exist within Scania but also externally. The purpose is to give suggestions for Scania on which quality assurance methods are suitable for Scania's low-volume assembly line. Today the current level of quality assurance in a low-volume line is considerable low and the production have many processes between start and delivery. The production start with an order initiation which prints out a list of assembly order and included parts. The processes are manually handled by one operator from the beginning to the end and the work includes assembly, material picking and quality control. Due to limitations and lack of equipment, the assembler have a lot of responsibility. The processes are also lacking of traceability and have a high risk for allowing deviations to be build in the product. The current processes leads to increased risks of rework, longer lead time and lower quality. The thesis project started with a literature study with the focus on quality, quality assurance and lean production. A current state analysis was done to gain knowledge of the processes and to identify problems within the current state. Identified problems were through observations, interviews and analysis of PFMEA document. The problems were risks that could affect quality of the product, and it was then categorized into three major risk groups; pick, place and tools. To seek which equipment there are to handle these risks, how other companies and departments are working with quality assurance, internal and external study visits were carried out. Internally within Scania; Smart Factory Lab, Engine Assembly and Chassis Assembly. Externally; Volvo Group Trucks Operations K¨opingand Volvo CE Arvika. The results of the visits were evaluated to create a solution to make a suitable suggestion in term of cost, quality and flexibility for Scania. The thesis project resulted in a study that showcase what quality assurance methods and equipment ex- isted on the market and what other companies are using to quality assure. The result is that for similar production, the companies are using rather similar methods and equipment. Equipment to handle risks, deviations involving picking materials and assembly. For Scania's low-volume production a solution and a recommendation of equipment was given. To handle the existing deviations and for upcoming similar low- volume production. Quality assurance equipment and methods are expensive but is considered necessary, a necessary cost and necessary waste. Scania is recommended to invest in short and long term solutions where the short term is to improve the current state. In a short term to secure the picking operations with easier solutions of dividing parts into boxes or trays on the cart during transportation from shelves. Installing pick to light connected to nutrunners for critical parts and further develop the digitalized checklist for improv- ing visualization. In longer term, Scania should invest in quality assurance equipment for low-volume lines. Prioritize and invest in creating infrastructure for connection between equipment and tools to secure critical parts in early stages of the project. Finally, create a communication between Scania's internal plants in order to further improve and share the quality assurance knowledge. Keywords: quality, quality assurance, wastes, deviations, low-volume, assembly Sammanfattning Scania genomg˚arnu en transformation fr˚anatt vara en leverant¨orav lastbilar, bussar och motorer till en lever- ant¨orav kompletta och h˚allbaratransportl¨osningar.Scanias transmissionsmontering i S¨odert¨alje st˚arinf¨or flera utmannande f¨or¨andringarkopplade mot framtidens drivlina och kunder. Utmaningar att s¨akrakvaliten av l˚agvolyms produkter, som ¨arprodukttyper av elektrifiering och hybridisering. Detta examensarbete har genomf¨orten unders¨okning av kvalitetss¨akringhos transmissionsmonteringens l˚agvolyms monteringsfl¨oden. Projektets m˚al¨aratt utv¨arderahur dagens metoder, utrustningar och processbeskrivningar f¨orkvalitetss¨akring hanteras och hur det kan till¨ampasi en l˚agvolyms monteringsfl¨oden.Syftet ¨aratt unders¨oka vilka kvalitetss¨akrings metoder som finns inom Scania och extern p˚amarknaden. D¨arefterta fram f¨orslagp˚ametoder och utrust- ningar som ¨arl¨ampligaf¨orScanias l˚agvolyms monteringsfl¨oden.Dagens niv˚aav kvalitetss¨akringsi l˚agvolyms monteringsfl¨odenanses vara l˚agoch produktionen inneh˚allerm˚angaprocesser fr˚anb¨orjantill slut. Pro- duktionen b¨orjarmed en initiering av order som skriver ut en monteringslista med inneh˚allandeartiklar. Processerna hanteras manuellt av en mont¨orfr˚anstart till slut och arbetet innefattar montering, materi- alplock och kvalitetskontroll. P˚agrund av begr¨ansningaroch brist p˚autrustningar har mont¨orenv¨aldigt stort ansvar. Processerna saknar ¨aven sp˚arbarhetoch har en h¨ogrisk f¨oratt till˚ataavvikelser att byggas i produkten. Nuvarande processerna leder till ¨okade risker f¨oromarbetning, ledtid och minskad kvalitet. Examensarbetet inleddes med en litteraturstudie med fokus p˚akvalitet, kvalitetss¨akringoch lean produk- tion. En nul¨agesanalysgenomf¨ordesf¨orf˚akunskaper om processerna och identifiera problem inom nul¨aget. Problemen identifierades genom observationer, intervju och analysering av PFMEA dokument. Identifierade problemen var risker som kunde p˚averka kvalitet p˚aprodukten, riskerna kategoriserades d¨areftertill tre hu- vudrisker; plock, montering och verktyg. F¨oratt s¨oka vilka utrustningar som kan hantera dessa risker, hur andra f¨oretagoch avdelningar arbetar med kvalitetss¨akringgenomf¨ordesinterna och externa studiebes¨ok.In- terna inom Scania; Smart Factory Lab, Motormontering och Chassimontering. Externa; Volvo Group Trucks Operations K¨opingoch Volvo CE Arvika. Resultaten av studiebes¨oken utv¨arderadestill att skapa en l¨osning f¨oratt g¨oraen l¨ampligf¨orslag f¨orScania med avseende p˚akostnad, kvalitet och flexibilitet. Examensarbetet resulterade i en studie som p˚avisarvilka kvalitetss¨akringsmetoder och utrustningar exis- terar p˚amarknaden och vad andra f¨oretaganv¨ander.Resultaten visar att f¨orliknande produktion, anv¨ander sig f¨oretagenlikadana metoder och utrustningar. Utrustningar som hanterar risker, avikelser som ber¨or materialplockning och montering. F¨orScanias l˚agvolymsproduktion har en l¨osningoch rekommendation av utrustningar presenteras. F¨oratt hantera nuvarande avvikelser och framtidens likande l˚agvolymsproduktion. Kvalitetss¨akringsutrustning och metoder ¨ardyra men anses vara n¨odv¨andigt,en n¨odv¨andigtkostnad och n¨odv¨andigtsl¨oseri. Scania rekommenderas att satsa p˚akort- och l˚angsiktigal¨osningard¨arde kortsiktiga ¨ar att f¨orb¨attranul¨aget. P˚akortsikt att s¨akra plocknings operationer med enkla l¨osningargenom att separ- era artiklar in till l˚adorp˚atransportvagnen vid transportion fr˚anhyllorna. Installera pick to light kopplad till skruvdragare f¨orkristiska artiklar och vidare utveckla digitaliserade checklistor f¨orb¨attrevisualisering. P˚al˚angsiktb¨orScania satsa p˚akvalitetss¨akringutrustningar f¨orl˚agvolymsmonteringsfl¨oden.Prioritera
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