Lean -työkalujen käyttöönoton suunnittelu VR Groupin kunnossapitoyksikölle

Lean –filosofia on ollut 1990 lähtien esillä yritysten toiminnan kehittämisessä niin laadun kuin tuottavuuden kehittämisen osalla. Filosofia on rakennettu Toyotan kehittämän Toyota Production Systemin (TPS) pohjalta ja sisältää useita eri menetelmiä yrityksen toimintojen jatkuvaan kehittämiseen yrityksen eri vaiheissa. Lean –filosofiassa yritystä kehitetään koko yrityksen olemassa olon ajan, voidaankin sanoa kyseessä olevan yrityksen elämäntapa. VR Group:n kunnossapitopalveluissa kehitetään parhaillaan VR Groupin laitteiden kunnossapitoa vastaamaan tulevaisuudessa avautuvaan kilpailuun. Kehittämishankkeen yhtenä kohteena on lean –ajattelun käyttöönottaminen kunnossapitopalvelun toiminnassa. Työssä selvitettiin leanin sisältämien menetelmien käyttöönottoa yhdelle VR Groupin kunnossapitoyksikölle, pääpainona virtauttaminen sekä jatkuva parantaminen. Työssä laadittiin kaksi virtauttamissuunnitelmaa VR Groupin kunnossapitoyksikölle, sekä esitellään vaihtoehtoja lean -työkaluista, joita kohdeyksikön kehittämisohjelmassa voitaisiin käyttää.

Decision making and decision support in service systems

This thesis is a literature study that develops a conceptual model of decision making and decision support in service systems. The study is related to the Ä-Logi, Intelligent Service Logic for Welfare Sector Services research project, and the objective of the study is to develop the necessary theoretical framework to enable further research based on the research project results and material. The study first examines the concepts of service and service systems, focusing on understanding the characteristics of service systems and their implications for decision making and decision support to provide the basis for the development of the conceptual model. Based on the identified service system characteristics, an integrated model of service systems is proposed that views service systems through a number of interrelated perspectives that each offer different, but complementary, implications on the nature of decision making and the requirements for decision support in service systems. Based on the model, it is proposed that different types of decision making contexts can be identified in service systems that may be dominated by different types of decision making processes and where different types of decision support may be required, depending on the characteristics of the decision making context and its decision making processes. The proposed conceptual model of decision making and decision support in service systems examines the characteristics of decision making contexts and processes in service systems, and their typical requirements for decision support. First, a characterization of different types of decision making contexts in service systems is proposed based on the Cynefin framework and the identified service system characteristics. Second, the nature of decision making processes in service systems is proposed to be dual, with both rational and naturalistic decision making processes existing in service systems, and having an important and complementary role in decision making in service systems. Finally, a characterization of typical requirements for decision support in service systems is proposed that examines the decision support requirements associated with different types of decision making processes in characteristically different types of decision making contexts. It is proposed that decision support for the decision making processes that are based on rational decision making can be based on organizational decision support models, while decision support for the decision making processes that are based on naturalistic decision making should be based on supporting the decision makers’ situation awareness and facilitating the development of their tacit knowledge of the system and its tasks. Based on the proposed conceptual model a further research process is proposed. The study additionally provides a number of new perspectives on the characteristics of service systems, and the nature of decision making and requirements for decision support in service systems that can potentially provide a basis for further discussion and research, and support the practice alike.

Tuotannonohjausmallin kehitys asiantuntijaorganisaatioon

Tässä diplomityössä tutkitaan sitä, miten kehitetään asiantuntijaorganisaatioon soveltuvaa tuotannonohjausmallia, jota käytettäisiin pääasiassa työkaluna asiantuntijatyön ohjauksessa. Kehitettävän mallin logiikan ja rakenteen tulisi tuottaa mitattavissa olevaa tietoa, jota pystytään käyttämään päätöksenteon tukena. Tutkimuksen tuloksena havaittiin, että asiantuntijatuotannon johtamisessa vanhojen perinteisten teollisuuden johtamismallien avulla johtaminen voi tuoda pelkkää haittaa ja työntekijöiden motivaatio laskee. Asiantuntija tarvitsee signaaleja työn tuottavuudesta ja säännöllistä läpikäyntiä johtajansa kanssa. Tuloksena saatiin erilaisia Excel-pohjaisia työkaluja, joiden malleja voidaan käyttää myös tulevaisuudessa yrityksen tuotantojärjestelmissä.

Lean –synty ja kehitysvaiheet

Lean-filosofia ei ole syntynyt hetkessä vaan sen periaatteet ovat syvällä historiassa. Leaniin kuuluvia asioita kuten standardointia, oikeaan tarpeeseen vastaamista ja tuotannon virtausta on käytetty aikaisemmin erilaisissa sovelluksissa. Lean-käsitteen pohjana on Toyota Production System, joka oli syntynyt vaadittaessa kustannustehokasta tuotantoa niukin resurssein. Lean syntyi, kun yhdysvaltalaistutkijat kiinnostuivat Toyotan käyttämistä tavoista valmistaa monia erilaisia malleja tehokkaasti. Leania voidaan pitää vastakohtana massatuotannolle. Lean levisi kulovalkean tavoin läntisessä teollisuusmaailmassa, vaikka sitä ei välttämättä edes kokonaisuudessa sovellettu. Leanista eroteltiin selkeitä työkaluja, joilla yritykset pääsivät kehittämään toimintaansa ja tehostamaan prosesseja. Työkalut otettiin innokkaasti käyttöön valmistuksessa ja niille kehitettiin myös muita sovelluskohteita. Leanin perimmäinen filosofia jäi usein huomiotta, eivätkä kaikki saaneet odotettuja tuloksia. 2000-lukuun mennessä leanin periaatteet oli tutkittu jo läpikotaisin. Ymmärrettiin leanin implementoinnin koskeneen koko organisaatiota, jotta sen periaatteita voitiin toteuttaa tehokkaasti. Lean on kuitenkin tähän päivään mennessä yhä hieman vieras asia sisältönsä puolesta vaikka termi alkaa olla tuttu jo kaikille monilla eri aloilla. Leanin tutkimus jatkuu ja sille löydetään yhä uusia sovelluskohteita, osin ratsastetaan termin maineella, osin ymmärretään oikein virtaustehokkuuden merkitys asiakkaan palvelemisessa.

A support system for evaluating a suitable joining method in the production of sheet metal goods

This report illustrates a comparative study of various joining methods involved in sheet metal production. In this report it shows the selection of joining methods, which includes comparing the advantages and disadvantages of a method over the other ones and choosing the best method for joining. On the basis of various joining process from references, a table is generated containing set of criterion that helps in evaluation of various sheet metal joining processes and in selecting the most suitable process for a particular product. Three products are selected and a comprehensive study of the joining methods is analyzed with the help of various parameters. The table thus is the main part of the analysis process of this study and can be advanced with the beneficial results. It helps in a better and easy understanding and comparing the various methods, which provides the foundation of this study and analysis. The suitability of the joining method for various types of cases of different sheet metal products can be tested with the help of this table. The sections of the created table display the requirements of manufacturing. The important factor has been considered and given focus in the table, as how the usage of these parameters is important in percentages according to particular or individual case. The analysis of the methods can be extended or altered by changing the parameters according to the constraint. The use of this table is demonstrated by pertaining the cases from sheet metal production.

Design of a Condition Monitoring System for a Glass Wool Production Line

Työn tarkoituksena oli suunnitella kunnonvalvontajärjestelmä kahdelle lasivillan tuotantolinjalle. Suunnitteluprosessin lisäksi työssä on esitelty erilaisia kunnonvalvontamenetelmiä. Työn alussa on kerrottu erilaisista kunnonvalvontamenetelmistä, joilla voidaan seurata erilaisten laitteiden ja koneiden toimintakuntoa.Erityisesti työssä on tarkasteltu teollisuudessa yleistyviä kunnonvalvonnan värähtelymittauksia. Työssä suunniteltu kunnonvalvontajärjestelmä perustuu viiteen eri menetelmään, jotka ovat värähtelymittaus, lämpötilanmittaus lämpökameralla, lämpötilanmittaus kannettavalla mittarilla, kuuntelu elektronisella stetoskoopilla ja pyörivien osien kunnontarkkailu stroboskoopilla. Kunnonvalvontajärjestelmän suunnittelu on tehty useassa eri vaiheessa. Ensin työssä on kartoitettu tuotannon kannalta tärkeimmät laitteet ja niiden mahdolliset vikaantumistavat. Seuraavaksi on valittu sopivat kunnonvalvontamenetelmät ja tehty mittaussuunnitelma, jossa on esitetty eri laitteille suoritettavat mittaukset ja mittausten aikavälit.Lopuksi työssä on esitelty muutama esimerkkitapaus kunnonvalvontamenetelmien käytöstä sekä kerrottu mahdollisista tulevaisuuden kehitysmahdollisuuksista.

Solid and liquid biofuels markets in Finland - a study on international biofuels trade

This study considered the current situation of solid and liquid biofuels markets and international biofuels trade in Finland and identified the challenges ofthe emerging international biofuels markets for Finland. The fact that industryconsumes more than half of the total primary energy, widely applied combined heat and power production (CHP) and a high share of biofuels in the total energy consumption are specific to the Finnish energy system. One third of the electricity is generated in CHP plants. As much as 27% of the total energy consumption ismet by using wood and peat, which makes Finland the leading country in the use of biofuels. Finland has made a commitment to maintain greenhouse gas emissions at the 1990 level at the highest during the period 2008-2012. The Finnish energypolicy aims to achieve the target, and a variety of measures are taken to promote the use of renewable energy sources and especially wood fuels. In this study, the wooden raw material streams of the forest industry were included the international biofuels trade in addition to biomass streams that are traded for energy production. In 2004, as much as 45% of the raw wood importedinto Finland ended up in energy production. The total international trading of biofuels was evaluated at 72 PJ, of which the majority, 58 PJ, was raw wood. About 22% of wood based energy in Finland originated from imported raw wood. Tall oil and wood pellets composed the largest export streams of biofuels. The annual turnover of international biofuels trade was estimated at about ¤ 90 million fordirect trade and at about ¤ 190 million for indirect trade. The forest industryas the biggest user of wood, and the producer and user of wood fuels has a central position in biomass and biofuels markets in Finland. Lately, the international aspects of Finnish biofuels markets have been emphasised as the import of rawwood and the export of wood pellets have increased. Expanding the use of biofuels in the road transportation sector would increase the international streams ofbiofuels in Finland. In coming years, the international trading of biomass for energy purposes can be expected to continue growing.

Product information management system design framework for production oriented company

Diplomityössä luodaan viitekehys tuotetiedonhallintajärjestelmän esisuunnittelua varten. Siinä on kolme ulottuvuutta: lisäarvontuotto-, toiminnallisuus- ja ohjelmistoulottuvuus. Viitekehys auttaa- tunnistamaan lisäarvontuottokomponentit, joihin voidaan vaikuttaa tiettyjen ohjelmistoluokkien tarjoamilla tuotetiedonhallintatoiminnallisuuksilla. Viitekehyksen järjestelmäsuunnittelullista näkökulmaa hyödynnetään tutkittavissa yritystapauksissa perustuen laskentamatriisin muotoon mallinnettuihin ulottuvuuksien välisiin suhteisiin. Matriisiin syötetään lisäarvontuotto- ja toiminnallisuuskomponenttien saamat tärkeydet kohdeyrityksessä suoritetussa haastattelututkimuksessa. Matriisin tuotos on tietyn ohjelmiston soveltuvuus kyseisen yrityksen tapauksessa. Soveltuvuus on joukko tunnuslukuja, jotka analysoidaan tulostenkäsittelyvaiheessa. Soveltuvuustulokset avustavat kohdeyritystä sen valitessa lähestymistapaansa tuotetiedonhallintaan - ja kuvaavat esisuunnitellun tuotetiedonhallintajärjestelmän. Viitekehyksen rakentaminen vaatii perinpohjaisen lähestymistavan merkityksellisten lisäarvontuotto- ja toiminnallisuuskomponenttien sekä ohjelmistoluokkien määrittämiseen. Määritystyö perustuu työssä yksityiskohtaisesti laadittujen menetelmien ja komponenttiryhmitysten hyödyntämiselle. Kunkin alueen analysointi mahdollistaa viitekehyksen ja laskentamatriisin rakentamisen yhdenmukaisten määritysten perusteella. Viitekehykselle on ominaista sen muunneltavuus. Nykymuodossaan se soveltuu elektroniikka- ja high-tech yrityksille. Viitekehystä voidaan hyödyntää myös muilla toimialoilla muokkaamalla lisäarvontuottokomponentteja kunkin toimialan intressien mukaisesti. Vastaavasti analysoitava ohjelmisto voidaan valita tapauskohtaisesti. Laskentamatriisi on kuitenkin ensin päivitettävä valitun ohjelmiston kyvykkyyksillä, minkä jälkeen viitekehys voi tuottaa soveltuvuustuloksia kyseiseen yritystapaukseen perustuen

Production of Biofuels by Fischer Tropsch Synthesis

Production of biofuel via biomass gasification followed by Fischer Tropsch synthesis is of considerable interest because of the high quality of fuels produced which do not contain sulphur and are free of carbon dioxide. The purpose of this Master’s thesis is to study feasibility production of biofuels integrated with Fischer Tropsch process using Aspen Plus simulation. The simulation results were used to size process equipment and carry out an economic evaluation. The results show that lowering the reactor temperature from 1000 oC - 850 oC and raising the water gas shift temperature from 500 oC - 600 oC can improve overall gas efficiency, which in turn leads to better production of ultra clean syngas for the Fischer Tropsch synthetic reactor. Similarly, the Fischer Tropsch offgas is converted into a gas turbine for power production, and finally biodiesel is produced as fuels for transportation.

Forest Biomass Resources and Technological Prospects for the Production of Second-generation Biofuels in Finland by 2020

Introduction of second-generation biofuels is an essential factor for meeting the EU’s 2020 targets for renewable energy in the transport sector and enabling the more ambitious targets for 2030. Finland’s forest industry is strongly involved in the development and commercialising of second-generation biofuel production technologies. The goal of this paper is to provide a quantified insight into Finnish prospects for reaching the 2020 national renewable energy targets and concurrently becoming a large-scale producer of forest biomass based second-generation biofuels feeding the increasing demand in European markets. The focus of the paper is on assessing the potential for utilising forest biomass for liquid biofuels up to 2020. In addition, technological issues related to the production of second-generation biofuels were reviewed. Finland has good opportunities to realise a scenario to meet 2020 renewable energy targets and for large-scale production of wood based biofuels. In 2020, biofuel production from domestic forest biomass in Finland may reach nearly a million ton (40 PJ). With the existing biofuel production capacity (20 PJ/yr) and national biofuel consumption target (25 PJ) taken into account, the potential net export of biofuels from Finland in 2020 would be 35 PJ, corresponding to 2–3% of European demand. Commercialisation of second-generation biofuel production technologies, high utilisation of the sustainable harvesting potential of Finnish forest biomass, and allocation of a significant proportion of the pulpwood harvesting potential for energy purposes are prerequisites for this scenario. Large-scale import of raw biomass would enable remarkably greater biofuel production than is described in this paper.

Review of water electrolysis technologies and design of renewable hydrogen production systems

An electric system based on renewable energy faces challenges concerning the storage and utilization of energy due to the intermittent and seasonal nature of renewable energy sources. Wind and solar photovoltaic power productions are variable and difficult to predict, and thus electricity storage will be needed in the case of basic power production. Hydrogen’s energetic potential lies in its ability and versatility to store chemical energy, to serve as an energy carrier and as feedstock for various industries. Hydrogen is also used e.g. in the production of biofuels. The amount of energy produced during hydrogen combustion is higher than any other fuel’s on a mass basis with a higher-heating-value of 39.4 kWh/kg. However, even though hydrogen is the most abundant element in the universe, on Earth most hydrogen exists in molecular forms such as water. Therefore, hydrogen must be produced and there are various methods to do so. Today, the majority hydrogen comes from fossil fuels, mainly from steam methane reforming, and only about 4 % of global hydrogen comes from water electrolysis. Combination of electrolytic production of hydrogen from water and supply of renewable energy is attracting more interest due to the sustainability and the increased flexibility of the resulting energy system. The preferred option for intermittent hydrogen storage is pressurization in tanks since at ambient conditions the volumetric energy density of hydrogen is low, and pressurized tanks are efficient and affordable when the cycling rate is high. Pressurized hydrogen enables energy storage in larger capacities compared to battery technologies and additionally the energy can be stored for longer periods of time, on a time scale of months. In this thesis, the thermodynamics and electrochemistry associated with water electrolysis are described. The main water electrolysis technologies are presented with state-of-the-art specifications. Finally, a Power-to-Hydrogen infrastructure design for Lappeenranta University of Technology is presented. Laboratory setup for water electrolysis is specified and factors affecting its commissioning in Finland are presented.

Advanced biofuel production: Engineering metabolic pathways for butanol and propane biosynthesis.

Greenhouse gases emitted from energy production and transportation are dramatically changing the climate of Planet Earth. As a consequence, global warming is affecting the living conditions of numerous plant and animal species, including ours. Thus the development of sustainable and renewable liquid fuels is an essential global challenge in order to combat the climate change. In the past decades many technologies have been developed as alternatives to currently used petroleum fuels, such as bioethanol and biodiesel. However, even with gradually increasing production, the market penetration of these first generation biofuels is still relatively small compared to fossil fuels. Researchers have long ago realized that there is a need for advanced biofuels with improved physical and chemical properties compared to bioethanol and with biomass raw materials not competing with food production. Several target molecules have been identified as potential fuel candidates, such as alkanes, fatty acids, long carbon‐chain alcohols and isoprenoids. The current study focuses on the biosynthesis of butanol and propane as possible biofuels. The scope of this research was to investigate novel heterologous metabolic pathways and to identify bottlenecks for alcohol and alkane generation using Escherichia coli as a model host microorganism. The first theme of the work studied the pathways generating butyraldehyde, the common denominator for butanol and propane biosynthesis. Two ways of generating butyraldehyde were described, one via the bacterial fatty acid elongation machinery and the other via partial overexpression of the acetone‐butanol‐ethanol fermentation pathway found in Clostridium acetobutylicum. The second theme of the experimental work studied the reduction of butyraldehyde to butanol catalysed by various bacterial aldehyde‐reductase enzymes, whereas the final part of the work investigated the in vivo kinetics of the cyanobacterial aldehyde deformylating oxygenase (ADO) for the generation of hydrocarbons. The results showed that the novel butanol pathway, based on fatty acid biosynthesis consisting of an acyl‐ACP thioesterase and a carboxylic acid reductase, is tolerant to oxygen, thus being an efficient alternative to the previous Clostridial pathways. It was also shown that butanol can be produced from acetyl‐CoA using acetoacetyl CoA synthase (NphT7) or acetyl‐CoA acetyltransferase (AtoB) enzymes. The study also demonstrated, for the first time, that bacterial biosynthesis of propane is possible. The efficiency of the system is clearly limited by the poor kinetic properties of the ADO enzyme, and for proper function in vivo, the catalytic machinery requires a coupled electron relay system.