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.

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.

Performance benchmarking and incentive regulation – considerations of directing signals for electricity distribution companies

After the restructuring process of the power supply industry, which for instance in Finland took place in the mid-1990s, free competition was introduced for the production and sale of electricity. Nevertheless, natural monopolies are found to be the most efficient form of production in the transmission and distribution of electricity, and therefore such companies remained franchised monopolies. To prevent the misuse of the monopoly position and to guarantee the rights of the customers, regulation of these monopoly companies is required. One of the main objectives of the restructuring process has been to increase the cost efficiency of the industry. Simultaneously, demands for the service quality are increasing. Therefore, many regulatory frameworks are being, or have been, reshaped so that companies are provided with stronger incentives for efficiency and quality improvements. Performance benchmarking has in many cases a central role in the practical implementation of such incentive schemes. Economic regulation with performance benchmarking attached to it provides companies with directing signals that tend to affect their investment and maintenance strategies. Since the asset lifetimes in the electricity distribution are typically many decades, investment decisions have far-reaching technical and economic effects. This doctoral thesis addresses the directing signals of incentive regulation and performance benchmarking in the field of electricity distribution. The theory of efficiency measurement and the most common regulation models are presented. The chief contributions of this work are (1) a new kind of analysis of the regulatory framework, so that the actual directing signals of the regulation and benchmarking for the electricity distribution companies are evaluated, (2) developing the methodology and a software tool for analysing the directing signals of the regulation and benchmarking in the electricity distribution sector, and (3) analysing the real-life regulatory frameworks by the developed methodology and further develop regulation model from the viewpoint of the directing signals. The results of this study have played a key role in the development of the Finnish regulatory model.

Russian Enterprise Restructuring - the Effect of Privatisation and Market Liberalisation on the Performance of Large Enterprises

The fundamental question in the transitional economies of the former Eastern Europe and Soviet Union has been whether privatisation and market liberalisation have had an effect on the performance of former state-owned enterprises. This study examines the effect of privatisation, capital market discipline, price liberalisation and international price exposure on the restructuring of large Russian enterprises. The performance indicators are sales, profitability, labour productivity and stock market valuations. The results do not show performance differences between state-owned and privatised enterprises. On the other hand, the expansion of the de novo private sector has been strong. New enterprises have significantly higher sales growth, profitability and labour productivity. However, the results indicate a diminishing effect of ownership. The international stock market listing has a significant positive effect on profitability, while the effect of domestic stock market listing is insignificant. The international price exposure has a significant positive increasing effect on profitability and labour productivity. International enterprises have higher profitability only when operating on price liberalised markets, however. The main results of the study are strong evidence on the positive effects of international linkages on the enterprise restructuring and the higher than expected role of new enterprises in the Russian economy.

Perspectives for the production and usage of wood chips as a source of energy in the North-West of Russia

The development of bioenergy on the basis of wood fuels has received considerable attention in the last decades. The combination of large forest resources and reliance on fossil fuels makes the issue of wood chips usage in Russia an actual topic for the analysis. The main objective of this study is to disclose the current state and perspectives for the production of wood chips and their usage as a source of energy in the North-West of Russia. The study utilizes an integrated approach to explore the market of wood chips on the basis of comprehensive analysis of documentation and expert opinions. The analysis of wood chips market was performed for eight regions of the North-West district of Russia within two major dimensions: its current state and perspectives in the nearest five years. The results of the study show a comprehensive picture of the wood chips market, including the potential for wood chips production, the specific features of production and consumption and the perspectives for the market development within the regions of the North-West district of Russia. The study demonstrated that the market of wood chips is underdeveloped in the North-West of Russia. The findings of the work may be used by forest companies for the strategic planning.

Data management as a part of performance management: Case study about production reporting development project

Because of the increased availability of different kind of business intelligence technologies and tools it can be easy to fall in illusion that new technologies will automatically solve the problems of data management and reporting of the company. The management is not only about management of technology but also the management of processes and people. This thesis is focusing more into traditional data management and performance management of production processes which both can be seen as a requirement for long lasting development. Also some of the operative BI solutions are considered in the ideal state of reporting system. The objectives of this study are to examine what requirements effective performance management of production processes have for data management and reporting of the company and to see how they are effecting on the efficiency of it. The research is executed as a theoretical literary research about the subjects and as a qualitative case study about reporting development project of Finnsugar Ltd. The case study is examined through theoretical frameworks and by the active participant observation. To get a better picture about the ideal state of reporting system simple investment calculations are performed. According to the results of the research, requirements for effective performance management of production processes are automation in the collection of data, integration of operative databases, usage of efficient data management technologies like ETL (Extract, Transform, Load) processes, data warehouse (DW) and Online Analytical Processing (OLAP) and efficient management of processes, data and roles.

Production scheduling tools' evaluation in a global telecommunications and electronics company

Tutkimuksen päätavoite on arvioida, ovatko neljä ohjelmistovaihtoehtoa riittäviä tuotannon aikataulutuksen työkaluja ja mikä työkaluista sopii toimeksiantajayritykselle. Alatavoitteena on kuvata tuotannon aikataulutuksen nyky- ja tahtotila prosessimallinnuksen avulla, selvittää työkalun käyttäjätarpeet ja määritellä priorisoidut valintakriteerit työkalulle.Tutkimuksen teoriaosuudessa tutkitaan tuotannon aikataulutuksen logiikkaa ja haasteita. Työssä tarkastellaan aikataulutusohjelmiston valintaa rinnakkain prosessinmallinnuksen kanssa. Aikataulutusohjelmistovaihtoehdot ja metodit käyttäjätarpeiden selvittämiseksi käydään läpi. Empiriaosuudessa selvitetään tutkimuksen suhde toimeksiantajayrityksen strategiaan. Käyttäjätarpeet selvitetään haastattelujen avulla jaanalysoidaan QFD matriisin avulla. Toimeksiantajayrityksen tuotannon aikataulutuksen nyky- ja tahtotilaprosessit mallinnetaan, jotta ohjelmistojen sopivuutta, aikataulutusprosessia tukevana työkaluna voidaan arvioida.Tutkimustuloksena ovatpriorisoidut valintakriteerit aikataulutustyökalulle eli käyttäjätarpeista johdetut tärkeimmät toiminnalliset ominaisuudet, järjestelmätoimittaja-arvio sekä suositukset jatkotoimenpiteistä ja lisätutkimuksesta.

A Feasibility Study of a Pelleting Plant as an Option for By Product Upgrading in Wood-Processing Industry

Tämän kannattavuustutkimuksen lähtökohtana oli se, että Yhtyneet Sahat Oy:n Kaukaan sahalla ja Luumäen jatkojalostuslaitoksella haluttiin selvittää pellettitehtaan kannattavuus nykyisessä markkinatilanteessa. Tämä työon luonteeltaan teknis-taloudellinen selvitys eli ns. feasibility study. Pelletöintiprosessi on tekniikaltaan yksinkertainen eikä edellytä korkea teknologian laitteita. Toimiala on maailmanlaajuisesti varsin uusi. Suomessa pellettimarkkinat ovat vielä pienet ja kehittymättömät, mutta kasvua on viime vuosina tapahtunut. Valtaosa kotimaan tuotannosta menee vientiin. Investoinnin laskentaprosessissa saadut tuotannon alkuarvot sekä kustannusrakenteen määrittelyt ovat perustana varsinaisille kannattavuuslaskelmille. Laskelmista on selvitetty investointeihin liittyvät yleisimmät taloudelliset tunnusluvut ja herkimpiä muuttujia on tutkittu ja pohdittu herkkyysanalyysiä apuna käyttäen.

Sheeting efficiency improvement through production planning and control development.

Arkitus on kartongin jatkojalostusmuoto, jonka tehokkuus muodostuu monen tekijän vaikutuksesta. Tämän työn tavoitteena oli parantaa arkitustehokkuutta tutkitussa kahden folioleikkurin arkittamossa tuotannonsuunnittelun ja tuotannonohjauksen kehittämisellä. Kartonkitehtaan sisäisessä jalostusketjussa arkitus on viimeinen vaihe, mikä tekee siitä pitkälti riippuvaisen edeltävistä konevaiheista, eli kartonkikoneista ja PE-päällystyskoneista. Pelkkä arkituksen tuotannonsuunnittelun huomiointi ei siis vielä takaa hyvää lopputulosta arkitustehokkuuden kannalta. Folioarkitustoiminta on hyvin asiakassuuntautunutta. Arkkikoot määräytyvät asiakkaiden omien tarpeiden perusteella, jolloin eri arkkikokojen kokonaismäärä kasvaa huomattavan suureksi. Viime vuosien trendinä on ollut tilauseräkokojen pieneneminen. Näiden tekijöiden yhteisvaikutuksena arkituksen tuotantoprosessille on ominaista erilaisten asetusten aiheuttama katkonaisuus. Lisäksi pelkästään yhden millimetrin muutos arkin leveydessä voi usein vaikuttaa arkitustehokkuuteen hyvinkin merkittävästi. Näistä syistä arkituksen tuotannonsuunnittelun apuvälineeksi tarvitaan tarkkuuteen ja joustavuuteen kykenevää tietojärjestelmää. Tehokkaan tuotannonohjauksen tueksi tarvitaan lisäksi erilaisia leikkuri- ja kartonkilaatukohtaisia raportteja. Työn teoriaosassa käsitellään tarkemmin arkitustoiminnan ominaisuuksia ja sen tehokkuuteen vaikuttavia tekijöitä. Lisäksi käsitellään tuotannonsuunnittelun ja tuotannonohjauksen periaatteita ja toimintoja.

Electric Motor and Frequency Converter Markets in Latin America and Especially in the Mining Industry of Chile

Latinalaisen Amerikan osuus maailmantaloudesta on pieni verrattuna sen maantieteelliseen kokoon, väkilukuun ja luonnonvaroihin. Aluetta pidetään kuitenkin yhtenä tulevaisuuden merkittävistä kasvumarkkinoista. Useissa Latinalaisen Amerikan maissa on teollisuutta, joka hyödyntää luonnonvaroja ja tuottaa raaka-aineita sekä kotimaan että ulkomaiden markkinoille. Tällaisia tyypillisiä teollisuudenaloja Latinalaisessa Amerikassa ovat kaivos- ja metsäteollisuus sekä öljyn ja maakaasun tuotanto. Näiden teollisuudenalojen tuotantolaitteiden ja koneiden valmistusta ei Latinalaisessa Amerikassa juurikaan ole. Ne tuodaan yleensä Pohjois-Amerikasta ja Euroopasta. Tässä diplomityössä tutkitaan sähkömoottorien ja taajuusmuuttajien markkinapotentiaalia Latinalaisessa Amerikassa. Tutkimuksessa perehdytään Latinalaisen Amerikan maiden kansantalouksien tilaan sekä arvioidaan sähkömoottorien ja taajuusmuuttajien markkinoiden kokoa tullitilastojen avulla. Chilen kaivosteollisuudessa arvioidaan olevan erityistä potentiaalia. Diplomityössä selvitetään ostoprosessin kulkua Chilen kaivosteollisuudessa ja eri asiakastyyppien roolia siinä sekä tärkeimpiä päätöskriteerejä toimittaja- ja teknologiavalinnoissa.

Production Control Principles in Printed Wiring Board Fabrication

Työn tavoitteena oli kuvata piirilevyvalmistaja Aspocomp Oy:n Espoon tehtaan tämän hetkinen tuotannonohjausperiaate ja tunnistaa siinä esiintyvät puutteet sekä kehittää vaihtoehtoinen tuotannonohjausperiaate piirilevyvalmistukseen. Vaihtoehtoisen ohjausperiaatteen lähtökohtana oli tuotannonohjauksen sopeuttaminen vaativaan ja jatkuvasti muuttuvaan liiketoimintaympäristöön. Työn teoreettinen osa keskittyi tuotannonohjauksen eri lähestymistapoihin. Kirjallisuuskatsauksessa esitetään eri tuotannonohjausperiaatteiden keskeiset sisällöt, jotka muodostavat rungon toimivalle tuotannonohjauskäytännölle. Työn kokeellinen osa keskittyi Espoon piirilevytehtaan tuotannonohjausperiaatteen selvittämiseen. Espoon piirilevytehtaan nykyisessä tuotannonohjausperiaatteessa havaittujen ongelmakohtien ja liiketoimintaympäristön vaatimusten perusteella kehitettiin vaihtoehtoinen tuotannonohjaustapa. Vaihtoehtoisen tuotannonohjaustavan päämääränä oli läpimenoajan lyhentäminen sekä tuotannon parempi hallittavuus. Vaihtoehtoinen toimintamalli tavoitteiden saavuttamiseksi perustuu pullonkaulateoriaan, jossa keskeisin muutos nykyiseen toimintamalliin oli puolivalmisteiden varastointi toimitusajan lyhentämiseksi sekä tuotantovolyymin heilahdusten vaikutusten vähentämiseksi. Työn kokeellisessa osassa ilmeni, että kysynnän muutokset ja kapasiteetin suunnittelun puute aiheuttivat ongelmia piirilevytehtaan tuotannonohjauksessa.

Description and implementation of cut calculation-method in a sawmill

Työn tavoitteena oli kuvata ja ottaa käyttöön sahauseräkohtaisen kannattavuuden laskentamenetelmä sahalle, sekä tehdä laskentamalli menetelmän tueksi. Sahauksen peruskäsitteiden jälkeen työssä on esitelty sahan tuotantoprosessi. Tuotantoprosessi on kuvattu kirjallisuuden ja asiantuntijoiden haastattelujen perusteella. Seuraavaksi kartoitettiin hyötyjä ja vaikutuksia, mitä laskentamenetelmältä odotetaan.. Kustannuslaskennan teoriaa selvitettiin kirjallisuuslähteitä käyttäen silmälläpitäen juuri tätä kehitettävää laskentamenetelmää. Lisäksi esiteltiin Uimaharjun sahalla käytettävät ja laskentaan liittyvät laskenta- ja tietojärjestelmät.Nykyisin sahalla ei ole minkäänlaista menetelmää sahauseräkohtaisen tuloksen laskemiseksi. Pienillä muutoksilla sahan tietojärjestelmään ja prosessikoneisiin voidaan sahauserä kuljettaa prosessin läpi niin, että jokaisessa prosessin vaiheessa sille saadaan kohdistettua tuotantotietoa. Eri vaiheista saatua tietoa käyttämällä saadaan tarkasti määritettyä tuotteet, joita sahauserä tuotti ja paljonko tuotantoresursseja tuottamiseen kului. Laskentamalliin syötetään tuotantotietoja ja kustannustietoa ja saadaan vastaukseksi sahauserän taloudellinen tulos.Toimenpide ehdotuksena esitetään lisätutkimusta tuotantotietojen automaattisesta keräämisestä manuaalisen työn ja virheiden poistamiseksi. Suhteellisen pienillä panoksilla voidaan jokaiselle sahauserälle kerätä tuotantotiedot täysin automaattisesti. Lisäksi kehittämäni laskentamallin tilalle tulisi hankkia sovellus, joka käyttäisi paremmin hyväksi nykyisiä tietojärjestelmiä ja poistaisi manuaalisen työvaiheen laskennassa.

Productivity of Business Services - Towards A New Taxonomy

Statistics show that the expanding service sector accounts already for three quarters of GDP in the developed economies. Moreover, there is abundant evidence on high variation in productive performance across the service industries. This suggests divergent technological and institutional trajectories within the tertiary sector. While conceptual knowledge on services and their performance has accumulated substantially, the overall landscape on productivity and competitiveness is still inconclusive. As noted by number of authors the research on service productivity is still in its infancy. The purpose of this paper is to develop further the analytical framework of service productivity. The approach is based on the notion that service definitions, classifications and performance measurement are strongly interdependent. Given the ongoing restructuring of businesses activities with higher information content, it is argued that the dichotomy between manufacturing and services should not be taken too far. Industrial evolution also suggests that the official industry classifications are increasingly outdated and new taxonomies for empirical research are therefore needed. Based on the previous analyses and new insights the paper clarifies the debated concept of service productivity and identifies the critical dimensions by which the service industries cluster. It is also demonstrated that the dimensions enable to construct new service taxonomies which bear essentially on productivity opportunities at the business level. Needles to say the key determinant explaining the development and potential of productivity growth is innovation activity. As an extensive topic of research, however, service innovation is tackled here only in a cursory way. The paper is constructed as follows: the first section focuses on the conceptual issues and evolving nature of service activities. A workable definition of service should capture the diversity of service activities, as well as the aspects of service processes, comprehensively. The distinctions and similarities between services and manufacturing are discussed, too. Section 2 deals with the service productivity, a persistent and controversial issue in academic literature and policy. With the assessments of strengths and weaknesses of the main schools new insights based on value creation will be brought in. Industry classifications and taxonomies are discussed in Section 3. It begins with a short analysis of the official classifications and their evaluation from the perspective of empirical research. Using well-known examples it is shown that the taxonomies on the manufacturing industries have a clear analogy with the business services. As there is a growing interest to regroup services too, the work to date, has been less systematic and inherently qualitative. Based on the earlier contributions threedimensional service taxonomy is constructed which highlight the key dimensions of productive performance. The main findings and implications are summed up in Section 4.

Knowledge Map of Research on Biofuels

This work highlights and analyzes the citations and co-citations by different authors, countries and institutions in series of researches on biofuel. These relations represent a knowledge map which shows the areas of research by different countries and authors. The contributions of different institutions were also shown. With this knowledge map developed, areas of research that still need more attention as well as the most important studies were highlighted. The software used for this analysis is Citespace which is developed by Chaomei Chen. Sources of information are articles retrieved from ISI Web of Science. Biofuel as a renewable form of energy is discussed. Its sources, types, methods of production, effects, market, and producers were discussed. Also plans and strategies that aim at boosting world biofuel market were listed as well as recent researches on it. Knowledge mapping, its types and methods as well as the method and software used for the analysis were also discussed.

Ultrafine grinding of FGD and phosphogypsum with an attrition bead mill and a jet mill : optimisation and modelling of grinding and mill comparison

Fine powders of minerals are used commonly in the paper and paint industry, and for ceramics. Research for utilizing of different waste materials in these applications is environmentally important. In this work, the ultrafine grinding of two waste gypsum materials, namely FGD (Flue Gas Desulphurisation) gypsum and phosphogypsum from a phosphoric acid plant, with the attrition bead mill and with the jet mill has been studied. The ' objective of this research was to test the suitability of the attrition bead mill and of the jet mill to produce gypsum powders with a particle size of a few microns. The grinding conditions were optimised by studying the influences of different operational grinding parameters on the grinding rate and on the energy consumption of the process in order to achieve a product fineness such as that required in the paper industry with as low energy consumption as possible. Based on experimental results, the most influential parameters in the attrition grinding were found to be the bead size, the stirrer type, and the stirring speed. The best conditions, based on the product fineness and specific energy consumption of grinding, for the attrition grinding process is to grind the material with small grinding beads and a high rotational speed of the stirrer. Also, by using some suitable grinding additive, a finer product is achieved with a lower energy consumption. In jet mill grinding the most influential parameters were the feed rate, the volumetric flow rate of the grinding air, and the height of the internal classification tube. The optimised condition for the jet is to grind with a small feed rate and with a large rate of volumetric flow rate of grinding air when the inside tube is low. The finer product with a larger rate of production was achieved with the attrition bead mill than with the jet mill, thus the attrition grinding is better for the ultrafine grinding of gypsum than the jet grinding. Finally the suitability of the population balance model for simulation of grinding processes has been studied with different S , B , and C functions. A new S function for the modelling of an attrition mill and a new C function for the modelling of a jet mill were developed. The suitability of the selected models with the developed grinding functions was tested by curve fitting the particle size distributions of the grinding products and then comparing the fitted size distributions to the measured particle sizes. According to the simulation results, the models are suitable for the estimation and simulation of the studied grinding processes.