H.P.T. Jellema

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Master thesis (1)

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Analysis and Optimization of a Machined Steel Kit Manufacturing Process

Master thesis (2013) - C.D. Rose (author) , J.F.J. Pruyn (mentor) , R. Voorend (mentor) , H.P.T. Jellema (mentor)

IHC Metalix, a producer of machined steel kits for the shipbuilding industry, is currently in the process of improving production efficiency by modifying an existing crane as well as by installing two additional cranes, a pallet conveyor, and a pallet storage rack. The exact effects of these improvements on the production process have not been quantified. Furthermore, the influences of the order properties on the production process not known. The goal of this project is to analyze the effect of the process upgrades and order properties on the production process. This project also aims to generate and test the effect of additional process improvements. Different order portfolios were created to represent the current order book of IHC Metalix and possible changes in the order book in the next few years. The influences of these order portfolios on the production process were determined using a sub-process capacity calculation and simulation model. The simulation model was also used to implement and test further improvements to the process. This study found that the process improvements installed in the past year should increase production capacity by approximately 25%. The plate cutting machines were found to be the process bottleneck for all of the order portfolios. Large ship types with simple structures (such as pipelaying vessels and construction projects) have a positive effect on the production capacity. Small vessels with complex structures (such as yachts, tugs, and inland cruise vessels) reduced the total production capacity. Coasters and dredgers were found to have little effect on the total production capacity. To improve the production process, it is recommended that two large part finishing tables are removed to make space for two additional flatrack positions. The printing algorithm of the vector plotters mounted to the cutting machines should also be improved as much as possible. If additional production capacity is required, a separate plate printer could also be installed. These improvements can increase the production capacity up to 18%.