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Optimization of pre-production processes

Improving processes in an engineer to order environment

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Optimization of pre-production processes

Improving processes in an engineer to order environment

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Kelvion refrigeration B.V is one of the world’s leading manufacturers of heat exchangers, who provide solutions for almost every industrial application imaginable, working in an engineer to order fashion to provide the customers with the utmost ability to customize their products.

In theory, 9 weeks are dedicated to receive (an order request), process, manufacture and deliver a product to allow for maximum satisfaction and a better position in the customized heat exchanger manufacturing sector. However, in a vast majority of these projects, the period defined by the company is not met and this is largely caused due to the pre-production processes which take up the majority of these 9 weeks dedicated for the entire process.
Consequently, concerns from the company’s representatives had risen, and for this reason, a graduation assignment was initiated to effectively allow for the identification of waste around the company’s pre-production processes and ultimately put forward improvements that would lead to process optimization. On this bass, the pre-production processes of the company were thoroughly investigated, mapped out, and improvements proposals were made with the aim to reach process optimization especially in terms of lead time reduction and productivity.

The main research question is as follows:
“How to improve the current situation of the pre-production processes in order to achieve process optimization?”
In pursuance of structuring the research report, the main research question is divided into 4 different sub-questions:
1- What is the current situation?
2- What are the tasks conducted in the processes and sub-processes found between AT1 and AT4?
3- What are the wastes and bottlenecks found in the processes?
4- What are the possible improvements to be implemented leading to the optimization of the processes?

These research sub-questions are ultimately answered through multiple different phases, which are indicated in the research roadmap displayed in figure 9 on page 26, designed following the lean six sigma methodology.
A theoretical framework was established focusing on relevant theories used throughout this research such the customer order de-coupling create awareness on the engineer to order processes, Lean management which is used to reduce waste around companies, and process mapping theories as another large objective requested by the company was the mapping of the processes.

Several different data collection methods were applied to gather comprehensive information about the processes. Firstly, interviews took place with multiple different employees around the company which had a function in the pre-production processes, and this allowed for a great understanding of the tasks that are conducted around the company, as well as some of their complaints about the processes. Observations were also applied to add to the range of qualitative data collection methods used in this report, providing the opportunity to identify a vast number of wastes and improvements.

Additionally, an ERP analysis was conducted to help understand the situation in a quantitative form of data, and allow for the recognition of where the issue stands in the company, as well as the number of projects conducted through the span of a year in terms of completed pre-production processes.
Following the execution of the research methods concluded in accordance to the theories used, wastes were identified, and a large list of improvements was established including, but not limited to, Training of staff, Creating additional work form, Utilizing existing and some process re-designs; leading to process optimization and an overall 19% reduction in terms of lead time.

Toon meer
OrganisatieHZ University of Applied Sciences
OpleidingTechnische bedrijfskunde
AfdelingDomein Technology, Water & Environment
PartnerKelvion Refrigiration B.V., Sint-Maartensdijk
Datum2022-02-03
TypeBachelor
TaalEngels

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