Operational Knowledge in Process Design

Työn tarkoituksena on selvittää, miten käyttötietämystä hyödynnetään prosessisuunnittelussa. Tavoitteena on löytää keinoja parantaa käyttötietämyksen hallintaa suunnitteluprosessin aikana ja selvittää, vaikuttaako tämä prosessisuunnittelun laatuun.Prosessisuunnittelun laatua arvioidaan seitsemällä kriteerillä, jotka ovat investointikustannukset, käyttökustannukset, turvallisuus, ympäristövaikutukset, käytettävyys, innovatiivisuus ja aikataulu. Suunnitteluprosessi jaetaan kolmeen vaiheeseen: esisuunnitteluun, perussuunnitteluun ja detaljisuunnitteluun. Prosessisuunnittelua, investointiprojektia, prosessisuunnittelun laatukriteerejä, suunnitteluprosessin eri vaiheita ja käyttötietämyksen luokittelua tarkastellaan yleisesti. Työssä selvitettiin käyttötietämyksen hyödyntämistä Kemiralla. Aluksi muotoiltiin yleisiä väittämiä käyttötietämyksen hyödyntämisestä Kemiran ulkopuolisten eri alojen asiantuntijoiden haastattelujen perusteella. Tämän jälkeen Kemiran prosessisuunnittelijat arvioivat väittämiä. Arvioiden perusteella tehtiin johtopäätöksiä yleisesti käyttötietämyksen hyödyntämisestä prosessisuunnittelussa. Seuraavaksi haastateltiin kahdessa erityyppisessä case-projektissa mukana olleita henkilöitä ja muotoiltiin yleiset väittämät näihin projekteihin sopiviksi. Projekteissa mukana olleet henkilöt arvioivat väittämiä, ja näiden arvioiden perusteella projekteja vertailtiin keskenään. Lopussa esitetään johtopäätökset kaikkien väittämien arvioiden perusteella. Johtopäätöksenä voidaan todeta, että käyttötietämystä voidaan hyödyntää kaikissa suunnittelun vaiheissa, mutta paras hyöty saadaan perus- ja detaljisuunnittelussa. Käyttötietämyksellä voidaan vaikuttaa joihinkin prosessisuunnittelun laatukriteereihin, kuten esimerkiksi käytettävyyteen ja turvallisuuteen enemmän kuin muihin. Kemiralle suositellaan nykyisten tiedonhallintamenetelmien kehittämistä, jotta käyttötietämyksen saatavuus ja sen siirtäminen paranisi. Pr

Improvement of Operational Efficiency effectiveness (OEE) using Six Sigma DMAIC Methodology — Case Bottomer line AD2378

Overall Equipment Effectiveness (OEE) is the key metric of operational excellence. OEE monitors the actual performance of equipment relative to its performance capabilities under optimal manufacturing conditions. It looks at the entire manufacturing environment measuring, in addition to the equipment availability, the production efficiency while the equipment is available to run products, as well as the efficiency loss that results from scrap, rework, and yield losses. The analysis of the OEE provides improvement opportunities for the operation. One of the tools used for OEE improvement is Six Sigma DMAIC methodology which is a set of practices originally developed to improve processes by eliminating defects. It asserts the continuous efforts to reduce variation in process outputs as key to business success, as well as the possibility of measurement, analysis, improvement and control of manufacturing and business processes. In the case of the Bottomer line AD2378 in Papsac Maghreb Casablanca plant, the OEE figures reached 48.65 %, which is below the accepted OEE group performance. This required immediate actions to achieve OEE improvement. This Master thesis focuses on the application of Six Sigma DMAIC methodology in the OEE improvement on the Bottomer Line AD2378 in Papsac Maghreb Casablanca plant. First, the Six Sigma DMAIC and OEE usage in operation measurement will be discussed. Afterwards, the different DMAIC phases will allow the identification of improvement focus, the identification of OEE low performance causes and the design of improvement solutions. These will be implemented to allow further tracking of improvement impact on the plant operations.

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.

Performance and Methodological Aspects in Positron Emission Tomography

Performance standards for Positron emission tomography (PET) were developed to be able to compare systems from different generations and manufacturers. This resulted in the NEMA methodology in North America and the IEC in Europe. In practices, the NEMA NU 2- 2001 is the method of choice today. These standardized methods allow assessment of the physical performance of new commercial dedicated PET/CT tomographs. The point spread in image formation is one of the factors that blur the image. The phenomenon is often called the partial volume effect. Several methods for correcting for partial volume are under research but no real agreement exists on how to solve it. The influence of the effect varies in different clinical settings and it is likely that new methods are needed to solve this problem. Most of the clinical PET work is done in the field of oncology. The whole body PET combined with a CT is the standard investigation today in oncology. Despite the progress in PET imaging technique visualization, especially quantification of small lesions is a challenge. In addition to partial volume, the movement of the object is a significant source of error. The main causes of movement are respiratory and cardiac motions. Most of the new commercial scanners are in addition to cardiac gating, also capable of respiratory gating and this technique has been used in patients with cancer of the thoracic region and patients being studied for the planning of radiation therapy. For routine cardiac applications such as assessment of viability and perfusion only cardiac gating has been used. However, the new targets such as plaque or molecular imaging of new therapies require better control of the cardiac motion also caused by respiratory motion. To overcome these problems in cardiac work, a dual gating approach has been proposed. In this study we investigated the physical performance of a new whole body PET/CT scanner with NEMA standard, compared methods for partial volume correction in PET studies of the brain and developed and tested a new robust method for dual cardiac-respiratory gated PET with phantom, animal and human data. Results from performance measurements showed the feasibility of the new scanner design in 2D and 3D whole body studies. Partial volume was corrected, but there is no best method among those tested as the correction also depends on the radiotracer and its distribution. New methods need to be developed for proper correction. The dual gating algorithm generated is shown to handle dual-gated data, preserving quantification and clearly eliminating the majority of contraction and respiration movement

New design of the frame for a permanent magnet generator

This thesis introduces a search for a new design of the frame for a permanent magnet generator mounted at a windmill. The objective of this work is to offer new design ideas for the stator frame - new concepts for connecting stator core to stator frame in a generator. Desired aims of new design concepts are: simplification of the structure production; decrease of material use; use of standard components; light weight of construction and etc. Thesis contains several new possible designs for the stator frame structure. Also, it has a list of possible connection concepts, which can be used to join the stator to the frame. All new ideas are described and compared according to its match to the desired purposes of the work. New design concepts are modeled using modern software. The main part of the Thesis contains several approximate computer models of the current and new offered constructions, description of loads and stress in the current stator frame. It has evaluation of the most important stress and load characteristics. The final design is a result of all previous research. It has a description of a new frame structure and joining concept for it. This structure matched main aims of work, but it does not have detailed design with dimensions and check calculations of the frame and welds. Thesis gives representation about design search, evaluation and comparison of new concepts of generator structure. Also, it gives general representation of renewable energy technology, knowledge about windmill turbines and its contents.

Minimization of the experimental workload for the prediction of pollutants propagation in rivers. Mathematical modelling and knowledge re-use

The present thesis in focused on the minimization of experimental efforts for the prediction of pollutant propagation in rivers by mathematical modelling and knowledge re-use. Mathematical modelling is based on the well known advection-dispersion equation, while the knowledge re-use approach employs the methods of case based reasoning, graphical analysis and text mining. The thesis contribution to the pollutant transport research field consists of: (1) analytical and numerical models for pollutant transport prediction; (2) two novel techniques which enable the use of variable parameters along rivers in analytical models; (3) models for the estimation of pollutant transport characteristic parameters (velocity, dispersion coefficient and nutrient transformation rates) as functions of water flow, channel characteristics and/or seasonality; (4) the graphical analysis method to be used for the identification of pollution sources along rivers; (5) a case based reasoning tool for the identification of crucial information related to the pollutant transport modelling; (6) and the application of a software tool for the reuse of information during pollutants transport modelling research. These support tools are applicable in the water quality research field and in practice as well, as they can be involved in multiple activities. The models are capable of predicting pollutant propagation along rivers in case of both ordinary pollution and accidents. They can also be applied for other similar rivers in modelling of pollutant transport in rivers with low availability of experimental data concerning concentration. This is because models for parameter estimation developed in the present thesis enable the calculation of transport characteristic parameters as functions of river hydraulic parameters and/or seasonality. The similarity between rivers is assessed using case based reasoning tools, and additional necessary information can be identified by using the software for the information reuse. Such systems represent support for users and open up possibilities for new modelling methods, monitoring facilities and for better river water quality management tools. They are useful also for the estimation of environmental impact of possible technological changes and can be applied in the pre-design stage or/and in the practical use of processes as well.

Mechanical closing of the paperboard package and the effect of the shape of paperboard package to its manufacturability

The main objective of this thesis was to design a hinge and a closing mechanism for the plastic rim of a paperboard package. Of the hinge and closing mechanisms the 3D-models were designed using SolidWorks program and the functionality of the mechanisms was tested with rapid prototype models. When a mechanism that worked was found, the manufacturability of the mechanisms was tested in an injection molding machine with changeable inserts. Another objective of this thesis was to test the effect of the shape of paperboard package to its manufacturability. The effect of the packages shape was tested with plastic tools made for three different shaped trays. Suggestions for further research were made according to the results of the thesis.

Tuulivoimalan generaattorin roottorin valmistuksen ja valmistuskustannusten arviointi

Diplomityössä on käsitelty tuulivoimalan generaattorin roottorin valmistusta ja magneettien kiinnitystä. Työ on osa projektia, jonka tarkoituksena on ollut tuottaa kohdeyritykselle vaihtoehtoinen tuulivoimalan generaattorin roottorirakenne. Työhön on koottu projektissa käsitellyt asiat roottorin valmistustekniikan osalta. Työssä on selvitetty kustannuksien kannalta paras vaihtoehto roottorin valmistamiseksi sisältäen kuljetukset ja magneettien kokoonpanon. Valmistusmenetelminä on vertailtu hitsausta ja valamista. Magneettien osalta tarkasteltiin uuden vaihtoehtoisen kiinnitysmenetelmän tuomia säästöjä nykyiseen ratkaisuun verrattuna. Uusien roottorien kustannuksia on verrattu nykyiseen rakenteeseen. Tutkimusmenetelminä on käytetty projektiryhmän palavereja, haastatteluja ja kirjallisuusselvityksiä. Lopputuloksena kohdeyritykselle luotiin uusi roottorikonsepti, jossa yhdistyvät edullisempi roottorin valmistus ja magneettien kiinnitys. Roottorin valmistaminen valamalla osoittautui selvästi edullisemmaksi kuin hitsaaminen levyistä. Magneettien kiinnitystä yksinkertaistettiin käyttämällä seostettuja magneetteja ja magneettikehyksiä. Roottorin konstruktiomuutoksien avulla mahdollistettiin suurempi magneettien määrä, joka mahdollistaa suuremman tehontuoton.

Antenna Design for Contactless IC Card Applications

Contactless integrated circuit cards are one form of application of radio frequency identification. They are used in applications such as access control, identification, and payment in public transport. The contactless IC cards are passive which means that both the data and the energy are transferred to the card without contact using inductive coupling. Antenna design and optimization of the design for contactless IC cards defined by ISO/IEC14443 is studied. The basic operation principles of contactless system are presented and the structure of contactless IC card is illustrated. The structure was divided between the contactless chip and the antenna. The operation of the antenna was covered in depth and the parameters affecting to the performance of the antenna were presented. Also the different antenna technologies and connection technologies were provided. The antenna design process with the parameters and the design tools isillustrated and optimization of the design is studied. To make the design process more ideal a target of development was discovered, which was the implementation of test application. The optimization of the antenna design was presented based on the optimization criteria defined in this study. The solution for the implementation of these criteria and the effect of each criterion was found. For enhancing the performance of the antenna a focus for future study was proposed.

Painediffusöörin suunnitteluperusteiden kehittäminen

Pesu on tärkeä osa sellun tuotantoprosessia. Eräs tapa toteuttaa sellun pesu on käyttää painediffusööriä. Painediffusööri toimii syrjäytyspesuperiaatteella, eli poistaa sellu-massasta keittolipeää paineistetun pesuveden avulla. Työssä on kehitetty painediffusöörin suunnittelun lähtökohtia keräämällä tietoa laitteen toiminnasta, rakenteesta, valmistuksesta sekä nykyisistä epäkohdista, joihin esitetään parannusmahdollisuuksia. Tärkeimmät kehitysalueet laitteessa ovat valmistus-toleranssien väljentäminen sekä sihdin pystysuuntaisen liikkeen tuottaminen. Laitteen valmistustoleranssit on analysoitu perusteellisesti, ja niiden väljentämis-mahdollisuuksia on tutkittu. Väljentämiseen ehdotetaan erilaisia keinoja. Sihdin liike tuotetaan tällä hetkellä hydrauliikalla. Hydrauliikkakomponenteille on koottu mitoitusohjeita, joiden jälkeen esitellään keinoja hydrauliikkajärjestelmän kehittämiseen. Lopuksi esitellään muita lineaarisen liikkeen tuottamisvaihtoehtoja, joilla hydrauliikan voisi korvata. Rakenteessa käytetyille valmistusmateriaaleille on etsitty olemassa olevat yleisimpien materiaalistandardien mukaiset nimikkeet materiaalinvalinnan helpottamiseksi jatkossa. Pääasiallisten valmistusmateriaalien lisäksi on kerätty tietoa myös vaihtoehtoisista konstruktiomateriaaleista sekä materiaalinvalinnasta ja tuotesuunnittelusta yleensä.

CFD Simulation of Two-phase and Three-phase Flows in Internal-loop Airlift

Airlift reactors are pneumatically agitated reactors that have been widely used in chemical, petrochemical, and bioprocess industries, such as fermentation and wastewater treatment. Computational Fluid Dynamics (CFD) has become more popular approach for design, scale-up and performance evaluation of such reactors. In the present work numerical simulations for internal-loop airlift reactors were performed using the transient Eulerian model with CFD package, ANSYS Fluent 12.1. The turbulence in the liquid phase is described using κ- ε the model. Global hydrodynamic parameters like gas holdup, gas velocity and liquid velocity have been investigated for a range of superficial gas velocities, both with 2D and 3D simulations. Moreover, the study of geometry and scale influence on the reactor have been considered. The results suggest that both, geometry and scale have significant effects on the hydrodynamic parameters, which may have substantial effects on the reactor performance. Grid refinement and time-step size effect have been discussed. Numerical calculations with gas-liquid-solid three-phase flow system have been carried out to investigate the effect of solid loading, solid particle size and solid density on the hydrodynamic characteristics of internal loop airlift reactor with different superficial gas velocities. It was observed that averaged gas holdup is significantly decreased with increasing slurry concentration. Simulations show that the riser gas holdup decreases with increase in solid particle diameter. In addition, it was found that the averaged solid holdup increases in the riser section with the increase of solid density. These produced results reveal that CFD have excellent potential to simulate two-phase and three-phase flow system.

Regional innovation strategies and sustainability in selected EU countries

This study focuses on regional innovation strategy (RIS) and sustainability aspects in selected regions of European Union (EU) countries. It is known that RIS helps a region to innovate locally and to compete globally and it is considered as one of the main policy tools of the EU for innovation support at a regional level. This study is conducted to explore the existence and adoption of RIS in different regions of selected EU countries, and to highlight and compare regional RIS characteristics. The study is also aimed at identifying the factors that characterise the formulation and implementation of RIS as well as the problems associated thereof. In this study, six regions of EU countries are considered: Päijät-Häme Region (Finland); London Region (United Kingdom); Mid-West Region (Ireland); Veneto Region (Italy); Eastern Region (Poland); and West Region (Romania). Data and information are collected by sending questionnaires to the respective regional authorities of these selected regions. Based on the gathered information and analysis, RIS or equivalent strategy document serves as a blueprint for forwarding innovative programmes towards regional sustainability. The objectives of RIS in these regions are found to be dependent on the priority sectors and state of the region’s development. The current environmental sustainability aspects are focused on eco-design, eco-products, and eco-innovation, although each region also has its own specific aspects supported by RIS. Likewise, regional policies typically follow the RIS yet translated in various sectoral focus or priority areas. The main enhancing factors supporting RIS among selected regions have some similarities and variations; among others, some regions are strongly supported by EU while others have support from own regional agencies, organisations and professional networks. RIS implementation is not without challenges and despite the differences in challenges, almost all of reviewed regions consider financial resource as a common problem. Generally, it is learned from this study that RIS and regional sustainability are reinforcing each other mutually. In this study, the strong focus is given towards environmental sustainability in the regions although regional sustainability also includes economic and social aspects. A well-focused and prioritised RIS is beneficial for regional sustainable development.

Hybridikomposiittien hyödyntäminen tuulivoimalan rakenteissa

Diplomityön tarkoituksena oli tutkia hybridikomposiittien soveltuvuutta tuulivoimalan osien tai osakokonaisuuksien rakennemateriaaliksi. Lähtökohtana oli selvittää erityisesti luonnonkuitukomposiitin materiaaliteknisten ominaisuuksien, etenkin lujuusominaisuuksi-en soveltuminen tuulivoiman rakenteisiin. Työn johdanto-osuudessa esitellään tuulivoiman rooli tämän päivän energiantuotannossa, yksittäisen tuulivoimalalaitoksen rakenne, rakenteiden suunnittelussa huomioitavat seikat, voimalan eri osien kuten tornin, lapojen ja nasellin yleisimmät valmistusmenetelmät, sekä muovien ja eri lujitteiden ohella puumuovikomposiitin materiaaliominaisuudet, valmistus-menetelmät ja yleisimmät käyttökohteet. Hybridikomposiittien lujuusominaisuuksia tutkittiin Lappeenrannan teknillisen yliopiston puutekniikan laboratoriossa suoritetuissa mittauksissa. Saatuja tuloksia verrattiin referens-situlosten ohella myös tällä hetkellä tuulivoimalan rakenteissa yleisesti käytettävien lasi- ja hiilikuidun, sekä teräksen ominaisuuksiin. Mittaustulosten perusteella bambu- ja lasikuitu-lujitteiset puumuovikomposiitit soveltuvat parhaiten tuulivoimalarakenteisiin, mutta niiden valmistaminen ekstruusiomenetelmällä on melko haasteellista.

Laatu ja tuottavuus hitsaavassa verkostossa

Diplomityössä tarkastellaan laadun ja tuottavuuden parantamisen keinoja hitsaavassa verkostossa MIG/MAG-hitsauksen osalta. Työn taustalla vaikuttaa Total Welding Management -menetelmä, mikä on hitsaustoimintojen kokonaisvaltaiseen johtamiseen ja hallintaan kehitetty toimintamalli. Työn teoriaosassa käsitellään laatuajattelua ja yritysyhteistyötä hitsaavan teollisuuden yrityskentässä sekä hitsauskustannuksiin vaikuttavia tekijöitä. Tutkimusosuus sisältää yritysverkoston nykytilan tarkastelun sekä kehitystoimenpiteitä kohti verkoston yhteistä toimintamallia saavuttaa tehokas ja kannattava yhteistyö. Hitsaustyön kustannukset määritetään suurelta osin suunnittelussa. Laatuun voidaan vaikuttaa merkittävästi hitsaustyötä edeltävissä toiminnoissa sekä hitsaajan työn tukemisella. Kokonaisvaltaisen hyödyn saavuttaminen hitsaustyön tuottavuuden parantamisessa vaatii kaikkien toimintojen tarkastelua sen sijaan, että tehostetaan vain hitsaamon toimintaa. Itse hitsaus voi olla vain pieni osa hitsaustoimintojen kokonaishallintaa. Toimintamallin luominen laadunvarmistukseen, suunnittelun ja valmistuksen yhteistyöhön sekä hitsaustoimintojen hallintaan mahdollistaa hitsaavan verkoston toiminnan tehostamisen sekä laadun paranemisen. Tämä saavutetaan viemällä toimintamalli osaksi jokapäiväistä työtä, lähelle valmistusta, ja ohjeistamalla, että jokainen tietää kuinka toimia. Esimerkiksi työssä tarkastellun yhden tuotteen osalta ohjeistus turhan työn vähentämiseksi tuotti 19 % tuotannon kasvun työvuoron aikana. Tilaus-toimitusketjun tuottavuuteen ja kannattavuuteen voidaan vaikuttaa merkittävästi käymällä läpi konkreettisesti valmistettavat tuotteet ja niihin liittyvät toiminnot. Diplomityössä tehtyjen tarkastelujen ja havaintojen avulla käytännön työ tulee jatkumaan yritysverkostossa tapahtuvassa kehitystyössä.

SOCIAL MEDIA IN INTERNATIONAL BRAND COMMUNICATION OF SMES - A multiple case study of small Finnish design-intensive companies

Social media is a rather new phenomenon which has revolutionised the world of online communication. However, academic research on how companies can benefit from social media is lacking. The research objective of this thesis was to examine the use of social media in international brand communication of small Finnish design-intensive companies. Therefore, this research contributes also to the research gap in SME branding. The focus was on communication targeted at consumers. The research was carried out as a mixed methods research employing the questionnaire and multiple case study methods. The questionnaire was used to gather preliminary information on Finnish design-intensive companies and to provide an eligible list of companies for deeper examination. Then, four case companies were studied in more depth. The empirical evidence of the case companies was mainly gathered through theme interviews. The results of the questionnaire shed light on the internationalisation of small Finnish designintensive companies. On average, the companies had internationalised rather quickly after they had been founded. However, the share of exports was rather low in most of the companies. The results revealed also that social media was already used widely in the exporting companies and the use can be expected to grow in future. The findings of the multiple case study suggest that branding activities in small Finnish designintensive companies are constrained by limited resources and skills. In addition, the branding activities are strongly guided by the vision and values of the entrepreneur(s) rather than extensive marketing research. The brand structure was simple in all case companies and they aimed at having a standardised brand image across markets. However, all case companies had faced a need for some adaptation of their international brand communication. Internationally important brand communication channels were international fairs, the internet, word-of-mouth and social media. Social media offered a cost-effective brand communication channel for the case companies. It was used for various purposes, such as creating brand awareness and affecting how the brand is perceived. The entrepreneurs found the use of social media to be rather easy and the case companies had not faced any major challenges. However, the companies had recognised that communication in social media requires consistency and planning. The planning was rather informal and stayed on a general level. Overall, the utilisation of social media in the case companies was limited by a lack of resources. It seemed to affect especially the follow-up of brand communication in social media which stayed rather superficial.