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Optimization of flashing manufacturing at Stratco Ltd Pty, South Australia
2008 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

This Masters thesis was undertaken at Stratco Ltd Pty in Adelaide, South Australia. The company refines thin steel sheets by profiling, pressing and bending sheet metal and has its own home improvement stores all around Australia. Stratco is one of the leading companies in the manufacture and delivery of flashings on short lead times. The production of flashings is customer driven and as such the manufacturing process needs to be very flexible. When producing flashings the material is cut out from a parent coil and is then slit into smaller pieces for further processing. When doing this, a lot of off cut, waste, is produced and thrown away. The amount of off cut that is produced depends on the operators skills. Stratco wants the flashing manufacturing process to be more efficient than it is today and in particular wants to reduce the amount of waste that is produced in order to save costs. It is also of interest to reduce the dependency on the operator who is cutting the material. The scope and aim of the project is, for these reasons, to find a more efficient way to produce flashings. During the project many different tools have been used to obtain a thorough understanding of how the flashing area works today. The writers of this thesis have participated in the production, conducted interviews, performed work sampling, collected and analysed data regarding what is produced and the quantities produced. To get input for new ideas for improvements benchmarking visits and market research for new technology was conducted. The data collected identified that there are specific patterns of colours, girths and gauges of flashings that are most frequently ordered. The data from the Slitting and blanking line also identified that there is a current off cut level of 23%. The analysis also identified that the major time in the Slitting and blanking line was spent on coil changes and writing on blanked sheets, 1/3 of the working time each. From all of the ideas generated two concepts were put together. They were evaluated against criteria from the specification of requirements. Since there was little difference in score between the two concepts it was decided to make a mix of the two concepts using the best parts from each. The final solution includes an automated guided vehicle system to do coil changes and a new cutting machine that cuts both lengthwise and across the coil.The cutting machine has integrated optimization software which layouts the most effective ways to cut the pieces. A label printer will be attached to the cutting machine to automatically label the individual pieces. The proposed solution will reduce the changeover time between two coils by 40% and the addition of the printer eliminates the time for writing on the blanked sheets. Tests were conducted with the optimization software and confirmed that the off cut that is thrown away can be reduced with 32%. Folders and trolleys are kept as today but the labour at the slitting machine can be used in other areas of the factory. It is recommended that Stratco look at which of their production plants would be best suited to this solution. Further investigation about the capacity of the cutting machine also has to be made before the solution is implemented. The capacity of the cutting machine is uncertain because it is a relatively new machine with new technology. Regarding the automated guided vehicle system, a strategic decision has to be made to confirm if Stratco wants to go towards a more automated production facility or not. The writers also recommend implementing a spreadsheet that was developed to facilitate the searching of off cuts, which can be used at the flashing area in its current state. Confidential until 2009-03-01

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Keyword [en]
Keyword [sv]
URN: urn:nbn:se:ltu:diva-56894ISRN: LTU-EX--08/044--SELocal ID: da2e8fd7-267e-44dc-a032-bb3a2b498828OAI: diva2:1030281
Subject / course
Student thesis, at least 30 credits
Educational program
Ergonomic Design & Production Engineering, master's level
Validerat; 20101217 (root)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

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