Asendiplaani ümberkujundamine ettevõtte Dagöplast AS tehases

Lõputöö eesmärgiks oli leida tehasele uus asendiplaan, mis kasutab tehase põrandapinda võimalikult optimaalselt, võimaldab vähendada materjalide liikumiste teepikkuseid vähemalt 10% ning lahendab probleemi, kus masinate tööalad paiknevad tõstuki sõiduteel. Autor kaardistas hetkeolukorra tehases, valis välja tooteportfellist kolm toodet, mille liikumiste põhjal võrrelda asendiplaanide optimaalsust ning mis peegeldavad kõige laialdasemalt kogu tooteportfelli liikumisi. Järgnevalt koostas autor kaks uut asendiplaani varianti võttes arvesse masinate mõõtmeid ning ruumi poolt seatavaid piiranguid. Spagetidiagrammi meetodi abil analüüsis ning võrdles autor kaht uut asendiplaani ja leidis neist sobivaima tehase jaoks. Autor analüüsis ka materjalide ladustamist tehases ning leidis ühele materjalide ladustamise alale lahenduse, kus on põrandapind on kõige tõhusamalt kasutatud. Uue asendiplaaniga õnnestus vähendada teepikkused keskmiselt 42%. Teepikkuste lühenemine võimaldab töötajal hoida kokku aega, mis kuluks väärtust mittelisava tegevuse teostamisele. Tööaja kokkuhoid keskmiselt 39 minutit tellimuse kohta võimaldab Eesti keskmise tunnitasu maksumuse tööandjale alusel kokku hoida aastas hinnanguliselt 14 238,90€. Uue asendiplaaniga lahendati probleemne piirkond praeguse tehase paigutuse juures, kus masinate tööalad paiknevad sõiduteel. Sellega paranes ka töökeskkonna ohutus. Lisaks esitati kaks ettepanekut materjalide ladustamise tõhustamiseks ühel laopinnal, mille tulemusel paraneks lao mahutavuse võimekus kuni 68%.

The following graduation thesis Redesigning Production Layou is based on the example of Dagöplast AS located in Käina, Hiiumaa. The primary reasons for redesigning the current layout are that two production lanes are partially situated on the driveway for a forklift, the material traveling distances in production are long, and the current floor area is not used to the best efficiency possible. The goal of this thesis is to propose a new, more efficient layout for the factory. The new layout should reduce the distances of material transportation by at least 10%, solve the problem, where the working areas of two production lines are situated on the driveway, and assure, that the available floor space is used most efficiently. The graduation thesis is composed of six chapters. Chapter 1 is introductory and describes the main problems with the current layout, setting goals for the thesis. Chapter 2 introduces the production company, on which the thesis is based. Chapter 3 covers the theoretical knowledge used for the thesis. The chapter is subdivided into three parts. Part 1 explains why it is important to plan production layouts and describes different types of layouts. Part 2 provides an overview of the spaghetti diagram method. Part 3 explains the blown film extrusion method for film production. Chapter 4 contains the empirical part of this thesis and is divided into two parts. Part 1 concentrates on solving the layout problems in the production part of the factory. Three products and their regular batch sizes were selected from the product pool, which embodies the movements of different kinds of products the best. Their movements were measured and analyzed and using the spaghetti method two new layouts were drafted. Part 2 analyzed the storage of material in the factory and proposed two new solutions. Chapter 5 describes the results achieved, one of the new layouts enabled to achieve an average decrease of 42% of the distance materials move in the production. The layout also solved the production areas on the driveway problem. The proposed solutions for material storage enable to increase the maximum capacity of the material storage up to 68%. Conclusions are drawn in Chapter 6.