Origins of production errors and significance of employee empowerment in reducing production error amount in sheet metal fabricating industry

The market place of the twenty-first century will demand that manufacturing assumes a crucial role in a new competitive field. Two potential resources in the area of manufacturing are advanced manufacturing technology (AMT) and empowered employees. Surveys in Finland have shown the need to invest in the new AMT in the Finnish sheet metal industry in the 1990's. In this run the focus has been on hard technology and less attention is paid to the utilization of human resources. In manymanufacturing companies an appreciable portion of the profit within reach is wasted due to poor quality of planning and workmanship. The production flow production error distribution of the sheet metal part based constructions is inspectedin this thesis. The objective of the thesis is to analyze the origins of production errors in the production flow of sheet metal based constructions. Also the employee empowerment is investigated in theory and the meaning of the employee empowerment in reducing the overall production error amount is discussed in this thesis. This study is most relevant to the sheet metal part fabricating industrywhich produces sheet metal part based constructions for electronics and telecommunication industry. This study concentrates on the manufacturing function of a company and is based on a field study carried out in five Finnish case factories. In each studied case factory the most delicate work phases for production errors were detected. It can be assumed that most of the production errors are caused in manually operated work phases and in mass production work phases. However, no common theme in collected production error data for production error distribution in the production flow can be found. Most important finding was still that most of the production errors in each case factory studied belong to the 'human activity based errors-category'. This result indicates that most of the problemsin the production flow are related to employees or work organization. Development activities must therefore be focused to the development of employee skills orto the development of work organization. Employee empowerment gives the right tools and methods to achieve this.

DATA WAREHOUSING IN A GLOBAL METAL INDUSTRIAL COMPANY

Työn tavoittena oli selvittää, miten tietovarastointi voi tukea yrityksessä tapahtuvaa päätöksentekoa. Tietovarastokomponenttien ja –prosessien kuvauksen jälkeen on käsitelty tietovarastoprojektin eri vaiheita. Esitettyä teoriaa sovellettiin käytäntöön globaalissa metalliteollisuusyrityksessä, jossa tietovarastointikonseptia testattiin. Testauksen perusteella arvioitiin olemassa olevan tiedon tilaa sekä kahden käytetyn ohjelmiston toimivuutta tietovarastoinnissa. Yrityksen operatiivisten järjestelmien tiedon laadun todettiin olevan tutkituilta osin epäyhtenäistä ja puutteellista. Siksi tiedon suora yrityslaajuinen hyödyntäminen luotettavien ja hyvälaatuisten raporttien luonnissa on vaikeaa. Lisäksi eri yksiköiden välillä havaittiin epäyhtenäisyyttä käytettyjen liiketoiminnan käsitteiden sekä järjestelmien käyttötapojen suhteen. Testauksessa käytetyt ohjelmistot suoriutuivat perustietovarastoinnista hyvin, vaikkakin joitain rajoituksia ja erikoisuuksia ilmenikin. Työtä voidaan pitää ennen varsinaista tietovarastoprojektia tehtävänä esitutkimuksena. Jatkotoimenpiteinä ehdotetaan testauksen jatkamista nykyisillä työkaluilla kohdistaen tavoitteet konkreettisiin tuloksiin. Tiedon laadun tärkeyttä tulee korostaa koko organisaatiossa ja olemassa olevan tiedon laatua pitää parantaa tulevaisuudessa.

Yliopiston yrityskehitystoiminnan vaikuttavuuden arviointi metalliteollisuuden pk-yrityksissä

Työn tavoitteena oli tutkia Lappeenrannan teknillisen korkeakoulun (LTKK) Koulutus-ja kehittämiskeskuksen (KOKE) metallitekniikan yrityskehityshankkeiden vaikuttavuutta osallistuneiden pk-yritysten näkökulmasta. Aluksi selvitettiin kirjallisuuden perusteella kehitystoiminnan tarpeita perinteisillä teollisuuden aloilla ja siinä esiintyneitä ongelmia. Aineistoa tehtyjen hankkeiden arvioimiseksi hankittiin teemahaastatteluilla vuosina 1997-2002 hankkeissa mukana olleilta yrityksiltä. Tutkimuksen perusteella KOKEn toteuttamat hankkeet ovat olleet yrityslähtöisiä ja tulleet todelliseen kehitystarpeeseen. Hankkeiden määrä on kasvanut voimakkaasti 1990 -luvulla ja yhä laajempi joukko yrityksiä on saatu yliopiston vaikutuspiiriin. KOKE on toiminnallaan onnistunut madaltamaan pk-yritysten kynnystä osallistua yliopistoyhteistyöhön. Hankkeiden vetäjät tuntevat pk-yritykset ja niiden toimintatavat, jolloin vuorovaikutus ei jaa liian etäiseksi. Hankkeilla saavutettuja tuloksia pidetään yrityksissä merkittävinä ja niihin ollaan tyytyväisiä. Yliopisto koetaan eri kehityspalvelujen tarjoajana luotettavana ja uskottavana, eikä sen koeta tekevän kehitystyöllään bisnestä. Tutkimuksen perusteella voidaan todeta, että KOKEn rooli yrityskehitystoiminnassa on merkittävä ja se on tärkeä toimija yhteydenpidossa pk-yritysten ja yliopiston välillä. Se on onnistunut voittamaan ne ongelmat, joita kehitystyössä yleensä esiintyy.

Designing of statically loaded sheet metal structures

The goal of this thesis is to give information to machine designers about how to design and size sheet metal structures and joints. Generally, the designing object is to lighten structures. To design structures that are light and can carry loads more effectively, designers have to be updated of new manufacturing techniques and new designing methods and criterions. With knowledge of this thesis, a designer can recognize objects and methods plus how and where it is possible to apply these new more effectively load carrying structures. The thesis gives answers to questions of corrosion and material planning, goes into joint types and manufacturing techniques of sheet metal structures. One of the main issues is to develop designers world of ideas to design right kind of products with new lasertechniques.

Fusion weld metal solidification:Continuum from weld interface to centerline

We present a brief résumé of the history of solidification research and key factors affecting the solidification of fusion welds. There is a general agreement of the basic solidification theory, albeit differing - even confusing - nomenclatures do exist, and Cases 2 and 3 (the Chalmers' basic boundary conditions for solidification, categorized by Savage as Cases) are variably emphasized. Model Frame, a tool helping to model the continuum of fusion weld solidification from start to end, is proposed. It incorporates the general solidification models, of which the pertinent ones are selected for the actual modeling. The basic models are the main solidification Cases 1…4. These discrete Cases are joined with Sub-Cases: models of Pfann, Flemings and others, bringing needed Sub-Case variables into the model. Model Frame depicts a grain growing from the weld interface to its centerline. Besides modeling, the Model Frame supports education and academic debate. The new mathematical modeling techniques will extend its use into multi-dimensional modeling, introducing new variables and increasing the modeling accuracy. We propose a model: melting/solidification-model (M/S-model) - predicting the solute profile at the start of the solidification of a fusion weld. This Case 3-based Sub-Case takes into account the melting stage, the solute back-diffusion in the solid, and the growth rate acceleration typical to fusion welds. We propose - based on works of Rutter & Chalmers, David & Vitek and our experimental results on copper - that NEGS-EGS-transition is not associated only with cellular-dendritic-transition. Solidification is studied experimentally on pure and doped copper with welding speed range from 0 to 200 cm/min, with one test at 3000 cm/min. Found were only planar and cellular structures, no dendrites - columnar or equiaxed. Cell sub structures: rows of cubic elements we call "cubelettes", "cell-bands" and "micro-cells", as well as an anomalous crack morphology "crack-eye", were detected, as well as microscopic hot crack nucleus we call "grain-lag cracks", caused by a grain slightly lagging behind its neighbors in arrival to the weld centerline. Varestraint test and R-test revealed a change of crack morphologies from centerline cracks to grainand cell boundary cracks with an increasing welding speed. High speed made the cracks invisible to bare eye and hardly detectable with light microscope, while electron microscope often revealed networks of fine micro-cracks.

The initial oxidation of transition metal surfaces

Due to their numerous novel technological applications ranging from the example of exhaust catalysts in the automotive industry to the catalytic production of hydro- gen, surface reactions on transition metal substrates have become to be one of the most essential subjects within the surface science community. Although numerous applications exist, there are many details in the different processes that, after many decades of research, remain unknown. There are perhaps as many applications for the corrosion resistant materials such as stainless steels. A thorough knowledge of the details of the simplest reactions occuring on the surfaces, such as oxidation, play a key role in the design of better catalysts, or corrosion resistant materials in the future. This thesis examines the oxidation of metal surfaces from a computational point of view mostly concentrating on copper as a model material. Oxidation is studied from the initial oxidation to the oxygen precovered surface. Important parameters for the initial sticking and dissociation are obtained. The saturation layer is thoroughly studied and the calculated results arecompared with available experimental results. On the saturated surface, some open questions still remain. The present calculations demonstrate, that the saturated part of the surface is excluded from being chemically reactive towards the oxygen molecules. The results suggest, that the reason for the chemical activity of the saturated surface is due to a strain effect occuring between the saturated areas of the surface.

WorldSkills - ammattitaitovalmennus osana kone- ja metallialan kilpailukykyä

Nykyaikain ammattitaitovalmennus alkaa olla verrattavissa huippu-urheiluun ja sen sisältämiin valmennusprosesseihin. Tämän tutkimuksen tavoitteena oli kartoittaa ne prosessit, joita käyttämällä ammattitaitovalmennettava saadaan tiedollisesti ja taidollisesti mandollisimman hyvin valmennettua WorldSkills-tason kilpailuihin. Valittuja prosesseja soveltaen ohjeistetaan CAD-suunnittelun valmennus ja kokonaisvaltainen valmistautuminen kilpailuihin. Hyvänä taustapohjana on tutkimuksen tekijän omakohtainen osallistuminen Taitaja-2007 kilpailun järjestämiseen lajivastaavana CAD-suunnittelussa. Tutkimuksessa tehtiin myös kartoitus kilpailutoiminnan vaikuttavuudesta ja sen mandollisista vaikutuksista kone- ja metallialan koulutukseen hakeutuvien nuorten määriin. Tutkimuksen pääkohteina olivat Taitaja-kilpailujen järjestäjinä toimineet paikkakunnat ja koulutuksenjärjestäjät peräkkäisiltä vuosilta eli Turku, Tampere ja Joensuu. Tämän lisäksi Helsingissä järjestetty WorldSkills-2005 kilpailu aiheutti positiivisia vaikutuksia koko ammattitaitovalmennuksen kenttään ja sen esille nostamiseen ammatillisessa koulutuksessa. Näitä tietoja ja prosesseja voidaan käyttää hyväksi ammattitaitovalmennuksen kanssa toimivien oppilaitoksien, työpaikkojen ja valmentajien sekä muiden asiasta kiinnostuneiden tahojen jatkossa tehtävään valmennukseen liittyvään kehitystyöhön.

Design of flywheel generator for a diesel hybrid working machine

The aim of this work is to design a flywheel generator for a diesel hybrid working machine. In this work we perform detailed design of a generator. Mobile machines are commonly used in industry: road building machines, three harvesting machines, boring machines, trucks and other equipment. These machines work with a hydraulic drive system. This system provides good service property and high technical level. Manufacturers of mobile machines tend to satisfy all requirements of customers and modernized drive system. In this work also a description of the frequency inverter is present. Power electronics system is one of the basic parts for structures perform in the project.

Venäläisten yritysten kansainvälistyminen

Tämän kandidaatintyön tavoitteena on selvittää ja analysoida venäläisten yritysten kansainvälistymistä investointien näkökulmasta. Aihetta tutkittiin Venäjältä ulospäin suuntautuneiden investointien valossa. Kansainvälistymistä analysoitiin konkreettisten yritysesimerkkien kautta. Työssä käytettiin lähteinä aikaisempia aiheesta tehtyjä tutkimuksia sekä esimerkkeinä olevien yritysten internetsivuja. Venäläisten yritysten kansainvälistyminen alkoi toden teolla vasta Neuvostoliiton hajoamisen jälkeen. Käytännössä yritysten kansainvälistyminen on lähtenyt kasvuun vasta 2000-luvulla. Viime vuosien aikana Venäjä on ollut yksi suurimmista ulospäin investoijista nousevien markkinatalouksien joukossa. Suurimmat Venäjältä ulospäin investoijat toimivat öljy- ja kaasuteollisuudessa sekä metalli- ja kaivosteollisuudessa. Kyseiset teollisuudenalat ovat riippuvaisia raaka-aineiden maailmanmarkkinahinnoista. Vuoden 2008 lopulla alkanut talouskriisi on alentanut raaka-aineiden hintoja ja näin vaikuttanut yritysten toimintaan. Yritykset ovat joutuneet talousvaikeuksiin, joka on vaikuttanut myös niiden investointeihin ulkomaille. Tällä hetkellä Venäjä on riippuvainen luonnonvaroihin perustuvista teollisuudenaloista, mutta tulevaisuudessa uusilla yrityksillä on mahdollisuuksia nousta kansainvälisien yritysten joukkoon. Raaka-aineiden hintojen kääntyessä jälleen nousuun myös luonnonvaroihin perustuvat yritykset tulevat nousemaan ahdingosta ja jatkamaan kansainvälistymistä.

Electroluminescence of silicon- and some metal oxides

In the present work electroluminescence in Si-SiO2 structures has been investigated. Electroluminescence has been recorded in the range of 250-900 nm in a system of electrolyte-insulator-semiconductor at the room temperature. The heating process of electrons in SiO2 was studied and possibility of separation it into two phases has been shown. The nature of luminescence centers and the model of its formation were proposed. This paper also includes consideration of oxide layer formation. Charge transfer mechanisms have been attended as well. The nature of electroluminescence is understood in detail. As a matter of fact, electron traps in silicon are the centers of luminescence. Electroluminescence occurs when electrons move from one trap to another. Thus the radiation of light quantum occurs. These traps appear as a result of the oxide growth. At the same time the bonds deformation of silicon atoms with SiOH groups is not excludes. As a result, dangling bonds are appeared, which are the trapping centers or the centers of luminescence.

Size Effect and Notch Size Effect in Metal Fatigue

It is a well known phenomenon that the constant amplitude fatigue limit of a large component is lower than the fatigue limit of a small specimen made of the same material. In notched components the opposite occurs: the fatigue limit defined as the maximum stress at the notch is higher than that achieved with smooth specimens. These two effects have been taken into account in most design handbooks with the help of experimental formulas or design curves. The basic idea of this study is that the size effect can mainly be explained by the statistical size effect. A component subjected to an alternating load can be assumed to form a sample of initiated cracks at the end of the crack initiation phase. The size of the sample depends on the size of the specimen in question. The main objective of this study is to develop a statistical model for the estimation of this kind of size effect. It was shown that the size of a sample of initiated cracks shall be based on the stressed surface area of the specimen. In case of varying stress distribution, an effective stress area must be calculated. It is based on the decreasing probability of equally sized initiated cracks at lower stress level. If the distribution function of the parent population of cracks is known, the distribution of the maximum crack size in a sample can be defined. This makes it possible to calculate an estimate of the largest expected crack in any sample size. The estimate of the fatigue limit can now be calculated with the help of the linear elastic fracture mechanics. In notched components another source of size effect has to be taken into account. If we think about two specimens which have similar shape, but the size is different, it can be seen that the stress gradient in the smaller specimen is steeper. If there is an initiated crack in both of them, the stress intensity factor at the crack in the larger specimen is higher. The second goal of this thesis is to create a calculation method for this factor which is called the geometric size effect. The proposed method for the calculation of the geometric size effect is also based on the use of the linear elastic fracture mechanics. It is possible to calculate an accurate value of the stress intensity factor in a non linear stress field using weight functions. The calculated stress intensity factor values at the initiated crack can be compared to the corresponding stress intensity factor due to constant stress. The notch size effect is calculated as the ratio of these stress intensity factors. The presented methods were tested against experimental results taken from three German doctoral works. Two candidates for the parent population of initiated cracks were found: the Weibull distribution and the log normal distribution. Both of them can be used successfully for the prediction of the statistical size effect for smooth specimens. In case of notched components the geometric size effect due to the stress gradient shall be combined with the statistical size effect. The proposed method gives good results as long as the notch in question is blunt enough. For very sharp notches, stress concentration factor about 5 or higher, the method does not give sufficient results. It was shown that the plastic portion of the strain becomes quite high at the root of this kind of notches. The use of the linear elastic fracture mechanics becomes therefore questionable.

Mobile system for pump working point estimation

In the current economy situation companies try to reduce their expenses. One of the solutions is to improve the energy efficiency of the processes. It is known that the energy consumption of pumping applications range from 20 up to 50% of the energy usage in the certain industrial plants operations. Some studies have shown that 30% to 50% of energy consumed by pump systems could be saved by changing the pump or the flow control method. The aim of this thesis is to create a mobile measurement system that can calculate a working point position of a pump drive. This information can be used to determine the efficiency of the pump drive operation and to develop a solution to bring pump’s efficiency to a maximum possible value. This can allow a great reduction in the pump drive’s life cycle cost. In the first part of the thesis, a brief introduction in the details of pump drive operation is given. Methods that can be used in the project are presented. Later, the review of available platforms for the project implementation is given. In the second part of the thesis, components of the project are presented. Detailed description for each created component is given. Finally, results of laboratory tests are presented. Acquired results are compared and analyzed. In addition, the operation of created system is analyzed and suggestions for the future development are given.

Faster for the master! : exploring issues of religious expression and alternative Christian identity within the Finnish Christian metal music scene

Populärkulturen har i dagens läge kommit att utgöra en allt mer viktig och central inspirationskälla för allt fler människors konstruktion av den egna religiösa identiteten även inom traditionella och institutionella kristna sammanhang. Denna avhandling belyser denna utveckling i ljuset av den finländska kristna metallmusik-kulturen - en sällsynt stark sammanblanding av protestantisk kristendom och en utpräglad och kontroversiell populärmusikform och dess kultur. Fokus riktas framför allt på hur den kristna metallmusik-kulturen blir meningsfull för sina medlemmar genom de sätt på vilka den konstrueras diskursivt, dvs. genom de sätt på vilka den representeras och talas om bland sina egna anhängare. Den diskursiva konstruktionen av den kristna metallmusik-kulturen utforskas på ett såväl bredare transnationellt som ett finländskt nationellt plan. Studien redogör även för den kristna metalmusikens och -kulturens huvudsakliga verbala, visuella och estetiska kännetecken. Uppbyggnaden och spridningen av dagens transnationella kristna metallmusik-kultur undersöks även i ljuset av det teoretiska konceptet scene. Avhandlingens centrala argument är att den kristna metallmusikscenen erbjuder sina medlemmar en mängd resurser för skapandet av ett alternativt och komplementärt religiöst uttrycksätt, religiös praxis och en alternativ kristen identitet.

Working Capital Management: a Bibliometric Study

This thesis is a study of articles published in scientific journals about working capital management using bibliometric methods. The study was restricted to articles published in 1990–2010 that deal with the whole working capital management topic not a single sub-area of it. Working capital is defined as current assets minus current liabilities; sometimes also a definition of inventory plus accounts receivable minus accounts payable is used. The data was retrieved from the databases ISI Web of Science and Sciverse Scopus. Articles about working capital management were found 23. Content analysis, statistical analysis and citation analysis was performed to the articles. The most cited articles found in citation analysis were also analyzed by nearly same methods. This study found that scientific research of working capital management seems not to be concentrated to specific persons, organizations or journals. The originality and novelty in many articles is low. Many articles studied relation between working capital management and profitability in firms or working capital management practices of firms using statistical analyses. Data in articles was firms of all sizes, except in developing economies only big firms were used. Interesting areas for future research could be surveys made about working capital management practices in firms, finding of best practices, tools for working capital management, inventing or improving alternative views to working capital management like process-oriented view and firm or industry specific studies.