Managing manufacturing data and improving its accuracy

There are two main objects in this study: First, to prove the importance of data accuracy to the business success, and second, create a tool for observing and improving the accuracy of ERP systems production master data. Sub-objective is to explain the need for new tool in client company and the meaning of it for the company. In the theoretical part of this thesis the focus is in stating the importance of data accuracy in decision making and it's implications on business success. Also basics of manufacturing planning are introduced in order to explain the key vocabulary. In the empirical part the client company and its need for this study is introduced. New master data report is introduced, and finally, analysing the report and actions based on the results of analysis are explained. The main results of this thesis are finding the interdependence between data accuracy and business success, and providing a report for continuous master data improvement in the client company's ERP system.

Veneer Properties Determination for Plywood Manufacturing

The objective in this Master's Thesis was to determine and verify quality criteria for veneer in plywood manufacturing. In plywood manufacturing the veneer quality has a decisive part how well it can be produced to a final product. Modern equipment run at high speed and capacity. These machines require a good quality veneer to be able to maintain them. The quality criteria determination was done after the dominant veneer properties were determined. This research focuses to the birch veneer quality determination. The machines involved in the veneer manufacturing are introduced in the materials and methods section. The different veneer properties are determined and the measuring devices to measure these properties are examined. There are many parts in veneer manufacturing and these have different requirements to the veneer quality. To determine and verify these properties for every machine was the most demanding part of this Master's Thesis. During the research some new ideas and ways to measure veneer properties were also tested. Veneer properties and quality was followed in a factory environment and in a test runs at the Raute. Different machines were followed carefully in the production environment while for example test pieces were taken from veneers that broke on the line. Sample pieces were tested on site or delivered to Nastola for more extensive testing. Based on the tests and research the criteria for veneer to every machine involved in the veneer production were created. These veneer quality tolerances are recommendations to ensure that the machine operation will not be affected by the veneer quality.

Warranty Practices and Costs in the Industry of Welding Machines Manufacturing

The objective of the master’s thesis is to define the warranty practices and costs in the welding machines manufacturing company and do a proposal for a warranty policy based on the practices and costs. The study include a disquisition of the warranty practices in the subsidiaries and distributor sales. The disquisition of the warranty practices introduces the information relates to warranty period, warranty costs, including repair, spare part and other costs, the practices with the replaced parts, the utilization rate of the eWarranty system and information relates to special arrangements in the warranties. The warranty costs are defined besides the group level also separately per regions and product families. From some product families the disquisition is done per products. In this study is also done a proposal for a warranty policy for the company. The proposal speaks out the length of warranty period, the compensation of the warranty costs, the practices with replaced parts and usage of eWarranty system.

Validation of plant dynamic model by online and laboratory measurements – a tool to predict online COD loads out of production of mechanical printing papers

COD discharges out of processes have increased in line with elevating brightness demands for mechanical pulp and papers. The share of lignin-like substances in COD discharges is on average 75%. In this thesis, a plant dynamic model was created and validated as a means to predict COD loading and discharges out of a mill. The assays were carried out in one paper mill integrate producing mechanical printing papers. The objective in the modeling of plant dynamics was to predict day averages of COD load and discharges out of mills. This means that online data, like 1) the level of large storage towers of pulp and white water 2) pulp dosages, 3) production rates and 4) internal white water flows and discharges were used to create transients into the balances of solids and white water, referred to as “plant dynamics”. A conversion coefficient was verified between TOC and COD. The conversion coefficient was used for predicting the flows from TOC to COD to the waste water treatment plant. The COD load was modeled with similar uncertainty as in reference TOC sampling. The water balance of waste water treatment was validated by the reference concentration of COD. The difference of COD predictions against references was within the same deviation of TOC-predictions. The modeled yield losses and retention values of TOC in pulping and bleaching processes and the modeled fixing of colloidal TOC to solids between the pulping plant and the aeration basin in the waste water treatment plant were similar to references presented in literature. The valid water balances of the waste water treatment plant and the reduction model of lignin-like substances produced a valid prediction of COD discharges out of the mill. A 30% increase in the release of lignin-like substances in the form of production problems was observed in pulping and bleaching processes. The same increase was observed in COD discharges out of waste water treatment. In the prediction of annual COD discharge, it was noticed that the reduction of lignin has a wide deviation from year to year and from one mill to another. This made it difficult to compare the parameters of COD discharges validated in plant dynamic simulation with another mill producing mechanical printing papers. However, a trend of moving from unbleached towards high-brightness TMP in COD discharges was valid.

Java 3D

Tämä insinöörityö kertoo Java 3D -ohjelmointirajapinnan perusteista ja sen käytöstä kolmiulotteisen tietokonegrafiikan luomisessa Java ohjelmointikielellä. Java 3D on rajapinta Java-ohjelmointikielelle, jonka avulla voidaan luoda ja käsitellä kolmiulotteista tietokonegrafiikkaa. Java 3D -rajapinnan avulla käsitellään kolmiulotteista tietokonegrafiikka erityisen maisemagraafimallin avulla. Maisemagraafi on binääripuuta muistuttava malli, joka mahdollistaa kolmiulotteisten kohteiden ja niille tapahtuvien muunnoksien käsittelyn hierarkisessa järjestyksessä. Työssä käydään läpi Java 3D -maisemagraafien luominen ja kolmiulotteisessa avaruudessa sijaitseville kappaleille tehtäviä perusoperaatioita kuten siirtoa ja kiertoa. Lisäksi käydään läpi myös erilaisia animoinnissa ja interaktiossa käytettäviä luokkia, joiden avulla ohjelmoija saa automatisoitua muunnoksia sekä käyttäjä voi antaa syötteitä hiirellä ja näppäimistöllä. Näiden lisäksi käydään läpi myös mallin valaistusta, varjoja, teksturointia sekä omien kolmiulotteisten mallien tuontia Java 3D -maailmaan. Opinnäytetyön yhteydessä on tehty myös kirjo erilaisia esimerkkejä, jotka ovat saatavilla verkkosivustolta osoitteessa http://www.pahvilaatikko.org/j3d lisäksi kopio verkkosivustosta löytyy myös opinnäytetyön mukana tulevalta cd-levyltä.

Mechanical Design of Hydraulic Vise

The general task of clamping devise is to connect the parts to the machining centers so that the work piece could be fixed on its position during the whole machining process. Additionally, the work piece should be clamped easily and rapidly by the machine users. The purpose of this Master’s thesis project was to develop a product design and find out the dimensioning of a hydraulic vise system for Astex Engineering OY, which was taking care of the general principles of product design and development during the design process. Throughout the process, the needs of manufacturing and assembling were taken into consideration for the machinability and minimization of the cost of manufacturing. The most critical component of the clamping devise was modeled by FEM for the issue of strength requirements. This 3D model was created with Solidworks and FEM-analysis was done with Cosmos software. As the result of this design work, a prototype of the hydraulic vise was manufactured for Astex Engineering OY and the practical test.

Characterisation of pigment particles by scanning electron microscope and image analysis programs

Coating and filler pigments have strong influence to the properties of the paper. Filler content can be even over 30 % and pigment content in coating is about 85-95 weight percent. The physical and chemical properties of the pigments are different and the knowledge of these properties is important for optimising of optical and printing properties of the paper. The size and shape of pigment particles can be measured by different analysers which can be based on sedimentation, laser diffraction, changes in electric field etc. In this master's thesis was researched particle properties especially by scanning electron microscope (SEM) and image analysis programs. Research included nine pigments with different particle size and shape. Pigments were analysed by two image analysis programs (INCA Feature and Poikki), Coulter LS230 (laser diffraction) and SediGraph 5100 (sedimentation). The results were compared to perceive the effect of particle shape to the performance of the analysers. Only image analysis programs gave parameters of the particle shape. One part of research was also the sample preparation for SEM. Individual particles should be separated and distinct in ideal sample. Analysing methods gave different results but results from image analysis programs corresponded even to sedimentation or to laser diffraction depending on the particle shape. Detailed analysis of the particle shape required high magnification in SEM, but measured parameters described very well the shape of the particles. Large particles (ecd~1 µm) could be used also in 3D-modelling which enabled the measurement of the thickness of the particles. Scanning electron microscope and image analysis programs were effective and multifunctional tools for particle analyses. Development and experience will devise the usability of analysing method in routine use.

Technology roadmap for new sales support and management system for crane manufacturing company

Sales configurators are essential tools for companies that offer complicated case specifically crafted products for customers. Most sophisticated of them are able to design an entire end product on the fly according to given constraints, calculate price for the offer and move the order into production. This thesis covers a sales configurator acquisition project in a large industrial company that offers cranes for its customers. The study spans the preliminary stages of a large-scale software purchase project starting from the specification of problem domain and ending up presenting the most viable software solution that fulfils the requirements for the new system. The project consists of mapping usage environment, use cases, and collecting requirements that are expected from the new system. The collected requirements involve fitting the new sales system into enterprise application infrastructure, mitigating the risks involved in the project and specifying new features to the application whilst preserving all of the admired features of the old sales system currently used in the company. The collected requirements were presented to a number of different sales software vendors who were asked to provide solution suggestions that would fulfil all the demands. All of the received solution proposals were exposed to an evaluation to determine the most feasible solutions, and the construction of evaluation criteria itself was a part of the study. The final outcome of this study is a short-list of the most feasible sales configurator solutions together with a description of how software purchase process in large enterprises work, and which aspects should be paid attention in large projects of similar kind.

Contract manufacturing networks structure and supply chain management

The usual objectives that companies have for subcontracting are studied in this thesis. The case company’s objectives for contract manufacturing now and in the future are identified. The main objective of the thesis is to create a focused model for the structure and supply chain management in the contract manufacturing network. This model is made for case company’s certain profit center. The different possibilities and their advantages and disadvantages for the structure and supply chain management are examined trough a theoretical review of literature. The possibilities found are then examined from the case company’s point of view. The case company point of view is established based on the opinions of the case company’s representatives. The outcome of the thesis is that the star shaped structure with supply chain management centralized to case company would be the best choice for the case company to manage the contract manufacture network.

3D Surface Modeling From Point Clouds

The goal of this thesis is to implement software for creating 3D models from point clouds. Point clouds are acquired with stereo cameras, monocular systems or laser scanners. The created 3D models are triangular models or NURBS (Non-Uniform Rational B-Splines) models. Triangular models are constructed from selected areas from the point clouds and resulted triangular models are translated into a set of quads. The quads are further translated into an estimated grid structure and used for NURBS surface approximation. Finally, we have a set of NURBS surfaces which represent the whole model. The problem wasn’t so easy to solve. The selected triangular surface reconstruction algorithm did not deal well with noise in point clouds. To handle this problem, a clustering method is introduced for simplificating the model and removing noise. As we had better results with the smaller point clouds produced by clustering, we used points in clusters to better estimate the grids for NURBS models. The overall results were good when the point cloud did not have much noise. The point clouds with small amount of error had good results as the triangular model was solid. NURBS surface reconstruction performed well on solid models.

Simulations of 3D Stripixel Detectors

Large Hadron Collider (LHC) is the main particle accelerator at CERN. LHC is created with main goal to search elementary particles and help science investigate our universe. Radiation in LHC is caused by charged particles circular acceleration, therefore detectors tracing particles in existed severe conditions during the experiments must be radiation tolerant. Moreover, further upgrade of luminosity (up to 1035 cm-2s-1) requires development of particle detector’s structure. This work is dedicated to show the new type 3D stripixel detector with serious structural improvement. The new type of radiation-hard detector has a three-dimensional (3D) array of the p+ and n+ electrodes that penetrate into the detector bulk. The electrons and holes are then collected at oppositely biased electrodes. Proposed 3D stripixel detector demonstrates that full depletion voltage is lower that that for planar detectors. Low depletion voltage is one of the main advantages because only depleted part of the device is active are. Because of small spacing between electrodes, charge collection distances are smaller which results in high speed of the detector’s response. In this work is also briefly discussed dual-column type detectors, meaning consisting both n+ and p+ type columnar electrodes in its structure, and was declared that dual-column detectors show better electric filed distribution then single sided radiation detectors. The dead space or in other words low electric field region in significantly suppressed. Simulations were carried out by using Atlas device simulation software. As a simulation results in this work are represented the electric field distribution under different bias voltages.

Ruuvipurkaimen DFMA

Tämän työn tarkoituksena oli soveltaa valmistusystävällisen ja kokoonpanon huomioivan suunnittelun(DFMA) periaatteita ajavalle ruuvipurkaimelle valmistuskustannusten alentamiseksi. Työn teoriaosassa esitellään valmistusystävällisen suunnittelun periaatteita. Yhtä tarkemmin noudatettua DFMA-menetelmää esitellään hieman enemmän. Teoriassa käsitellään myös valmistuskustannusten laskentaa, lähinnä hitsauksen ja koneistuksen osalta. Ruuvipurkaimen rakenteeseen perehdyttiin tekemällä siitä 3D-malli. Purkaimen valmistuskustannukset selvitettiin ja kustannusten painopisteet määritettiin. Niiden pohjalta valittiin kohteet joihin paneuduttiin ja joihin sovellettiin DFMA:n periaatteita. Ruuvipurkaimen valmistettavuuden parantamisessa saavutettiin tavoite, 10 % kustannussäästö valmistuskustannuksissa. Valmistettavuutta saatiin paremmaksi DFMA-menetelmiä soveltaen ja sitä kautta tuli kustannussäästöjä. Ostokomponenttien toimittajakartoituksella saatiin myös kustannuksia karsittua. Käytetty DFMA-menetelmä hieman sovellettuna oli tälle tuotteelle toimiva vaihtoehto. Jatkamalla valmistusystävällistä suunnittelua kalleimmille osille, saataisiin enemmän kustannussäästöjä mihin tässä työssä päästiin.

Engendering Group Support Based Foresight for Capital Intensive Manufacturing Industries - Case Paper and Steel Industry Scenarios by 2018

In recent times of global turmoil, the need for uncertainty management has become ever momentous. The need for enhanced foresight especially concerns capital-intensive industries, which need to commit their resources and assets with long-term planning horizons. Scenario planning has been acknowledged to have many virtues - and limitations - concerning the mapping of the future and illustrating the alternative development paths. The present study has been initiated to address both the need of improved foresight in two capital-intensive industries, i.e. the paper and steel industries and the imperfections in the current scenario practice. The research problem has been approached by engendering a problem-solving vehicle, which combines, e.g. elements of generic scenario process, face-to-face group support methods, deductive scenario reasoning and causal mapping into a fully integrated scenario process. The process, called the SAGES scenario framework, has been empirically tested by creating alternative futures for two capital-intensive industries, i.e. the paper and steel industries. Three scenarios for each industry have been engendered together with the identification of the key megatrends, the most important foreign investment determinants, key future drivers and leading indicators for the materialisation of the scenarios. The empirical results revealed a two-fold outlook for the paper industry, while the steel industry future was seen as much more positive. The research found support for utilising group support systems in scenario and strategic planning context with some limitations. Key perceived benefits include high time-efficiency, productivity and lower resource-intensiveness. Group support also seems to enhance participant satisfaction, encourage innovative thinking and provide the users with personalised qualitative scenarios.

Effects of Surface Properties and Wood Modification into Direct Printing on Wood

Building industry is a high volume branch which could provide prominent markets for wood based interior decoration solutions. Competition in interior decoration markets requires versatility in appearance. Versatility in wood appearance and added value could be achieved by printing grain patterns of different species or images directly onto wood. The problem when planning wood printing’s implementing into durable applications is basically how to transfer a high quality image or print sustainably onto wood, which is porous, heterogeneous, dimensionally unstable, non-white and rough. Wood preservation or treating, and modification can provide durability against degradation but also effect to the surface properties of wood which will effect on printability. Optimal adhesion is essential into print quality, as too high ink absorbance can cause spreading and too low ink absorbance cause pale prints. Different printing techniques have different requirements on materials and production. The direct printing on wood means, that intermedias are not used. Printing techniques with flexible printing plates or in fact non-impact techniques provide the best basis for wood printing. Inkjet printing of wood with different mechanical or chemical surface treatments, and wood plastic composite material gave good results that encourage further studies of the subject. Sanding the wood surface anti-parallel to the grain gave the best overall printing quality. Spreading parallel to the grain could not be avoided totally, except in cases where wood was treated hydrophobic so adhesion of the ink was not sufficient. Grain pattern of the underlying wood stays clearly visible in the printed images. Further studies should be made to fine tune the methods that already gave good results. Also effects of moisture content of wood, different inks, and long-term exposure to UV-radiation should be tested.

Defining the location factors of new manufacturing site in chemical industry

The objective of this thesis is to examine the factors that have an impact on the location decision of new manufacturing site and to create the relative order of importance of these factors by analytic hierarchy process (AHP). The decision making process especially related to the location selection and the measurement of the location factors are also examined. In theoretical part the character of decision making process and the relevant methods are introduced. Based on the previous studies of other researchers, the location factors are examined and the main research method, analytic hierarchy process, is also introduced. The empirical part of the study mainly follows the phases of decision making process and is emphasized on the main stages of analytic hierarchy process; building the hierarchy, defining the priorities and analyzing the results. The hierarchy is constructed from seven main criteria which all have several sub criteria. The evaluation of the hierarchy is implemented at the group decision making –laboratory and there can be seen significant differences between the importance of criteria. The final stage in the study is to create the appropriate measurement scales to the chosen criteria.