Kustannusten ja ajan sitoutuminen tuotteeseen elintarviketeollisuuden arvoverkostossa

Tämä pro gradu -tutkielma käsitteleekustannusten ja ajan analysointia elintarviketeollisuuden arvoverkostossa. Teoriaosuuden kantavia käsitteitä ovat arvoverkosto, Lean Management -ideologia, Value Stream Mapping ja Supply Chain Time and Cost Mapping. Tutkimus toteutetaan case - tutkimuksena, ja siinä on piirteitä niin kvalitatiivisesta kuin kvantitatiivisesta tutkimusasetelmasta. Teoriaosuuden lähteinä on käytetty tieteellisissä julkaisuissa ilmestyneitä journal -artikkeleita sekä alan kirjallisuutta. Tutkimus liittyy olennaisena osana Elintarviketeollisuuden Uudistuva Liiketoiminta -projektiin ja antaa tätä kautta kontekstin muille tutkimuksille sekä konkreettisenesimerkin kyseisestä arvoverkostosta. Empiirisen osan case-yrityksinä ovat Saarioinen Oy, Tuoretie Oy ja Ruokakesko Oy. Analyysin kohteena onLiha-Saarioisten valmistama karjalanpiirakka-tuoteryhmä. Konkreettisena tutkimustuloksena on karjalanpiirakan prosessikuvaus koko arvoketjun matkalta, kustannuskertymä, aikaperusteinen analyysi ja kustannus-aika-kuvaaja. Lisäksi arvoketjun matkalla tehdyistä haastatteluista on kerätty kehitysehdotuksia sekä samalla etsitty hukkatoimintoja. Tuloksista voi tehdä sen johtopäätöksen, että karjalanpiirakka on tyypillinen elintarvike, jonka kustannuksista suurin osa on raaka-aineita ja tuotannon työtä. Aikaa arvoketjussa kuluu eniten kaupan hyllyllä. Organisaatioidenyhteistyöllä aikaa ja sitä kautta kustannuksia olisi kuitenkin mahdollisuus vielä karsia.

Osavalmistuksen kustannustehokkuuden arviointi

Tämän diplomityön tarkoituksena oli selvittää osavalmistuksen kustannustehokkuutta Ruukki Engineering Seinäjoen palvelukeskuksessa. Osavalmistuksessa osia leikataan, särmätään ja viimeistellään kokoonpanohitsaukseen soveltuviksi komponenteiksi. Kustannustehokkuuden selvittämisessä käytettiin aikaan perustuvia mittausmenetelmiä, joiden pohjalta laskettiin tuotteen toteutuneita kustannuksia. Toteutuneita kustannuksia verrattiin hinnoittelutaulukoihin. Vertailussa havaittiin, että kaikkia työvaiheita ei ollut hinnoiteltu lainkaan. Erot hinnoittelun ja toteutuneiden kustannusten välillä olivat merkittäviä. Työssä tutkittiin myös jalostavan ajan osuutta kokonaisläpäisyajasta. Mitattuja tietoja verrattiin kahteen aikaisemmin tehtyyn tutkimukseen. Osavalmistuksessa aikaa kuluu paljon välivarastoissa ja työvaiheiden läpäisyajat olivat joidenkin työvaiheiden kohdalla pitkiä. Diplomityön tulokset olivat vertailukelpoisia muiden tutkimustenkanssa ja olivat ennalta asetettujen hypoteesien mukaisia.

JOHDON LASKENTATOIMI KÄRKIYRITYSVERKOSTOISSA Soveltamismahdollisuudet ja yritysten tarpeet

Tutkimus tarkastelee johdon laskentatoimea yritysverkostoissa. Tutkimuksen tavoitteena on lisätä ymmärrystä koskien sitä, millaisia tarpeita verkostoituneilla yrityksillä on johdon laskentatoimen suhteen ja millaiset ovat verkostotasoisten laskentajärjestelmien soveltamismahdollisuudet. Johdon laskentatoimea ja yritysverkostoja on tutkittu erillisinä alueina jo varsin pitkään, mutta verkostoituneen toimintamuodon yleistymisestä huolimatta johdon laskentatoimen tutkimus nimenomaan verkostoympäristössä onvasta alkuvaiheessa. Tämä tutkimus on toteutettu suomalaisissa verkostoituneissa metalliteollisuusyrityksissä. Tutkitut verkostot muodostuvatverkoston ydinyrityksestä ¿ kärkiyrityksestä - ja sen ympärille ryhmittyneistä pienistä toimittajayrityksistä. Tutkimus on toteutettu käyttäen teemahaastatteluja, joita suoritettiin neljässä eri yritysverkostossa. Tutkimusote on luonteeltaan laadullinen ja pääosin kuvaileva. Verkostojen laskentatoimen tutkimuksessa pienten toimittajayritysten näkemykset ja asenteet laskennan kehittämistä kohtaan ovat jääneet taka-alalle. Tämän tutkimuksen keskeisenä näkökulmana on juuri verkostoituneiden pk-yritystentarpeet, asenteet ja mahdollisuudet osallistua laskentatoimen kehitystyöhön. Tutkimuksessa tarkastellaan johdon laskentatoimea yleisellä tasolla, eikä rajauduta yksittäisiin menetelmiin. Tutkimus toi esille joitakin informaatiotarpeita verkostotasolla. Useita jalostusvaiheita eri yrityksissä käsittävässä tuotannossa vaikeutena on tietää tarkalleen missä tilaus etenee ja milloin tilaus saapuu yritykseen jalostettavaksi. Toimittajayritykset kaipaavat myös tarkempaa ja pidemmän ajanjakson kattavaa tietoa verkoston kärkiyrityksen tilauskannasta. Informaatiopuutteet aiheuttavat turhaa työtä ja vaikeuttavat resurssien ohjausta. Tutkituissa verkostoissa suunnittelua avustavalle budjetoinnille olisi tarpeita, mutta yhteistä budjetointia ei ole käytännössä toteutettu. Verkostojen laskentatoimessa kustannusten avoin esittäminen kumppaneille tai yleisemmin avoimuus koskien muitakin toiminnan mittareita on keskeisin tekijä, johon verkoston laskentatoimen toteuttaminen tiivistyy. Tutkituista verkostoista kahdessa avoimuus toteutui koskien kustannuksia, kahdessa muussa verkostossa kärkiyritykset eivät nähneet toimittajien kustannustietoja verkoston kilpailukyvyn kannalta merkittäväksi. Kustannusten avoimen esittämisen taustatekijöinä korostuivat kärkiyrityksen tuki, monimutkaisten konstruktioiden aiheuttamat hinnoitteluongelmat ja kannattavan asiakassuhteen varmistaminen. Verkostolaskennan kehittämisessä kärkiyrityksen rooli korostuu. Jos toimittajayritykset eivät tunnista verkostolaskennan tarjoamia mahdollisuuksia toiminnan yhteisessä kehittämisessä ja ohjaamisessa, on kärkiyrityksen pystyttävä perustelemaan toimittajille uskottavasti mitä hyötyä laskentajärjestelmistä on koko verkostolle ja erityisesti toimittajayrityksille. Tutkittujen yritysten on pystyttävä rutinoimaan nyt yleisellä tasolla toimiva keskustelu järjestelmälliseksi suunnittelu- ja ohjaustyöksi. Hyvät kokemuksetyksinkertaisistakin laskenta- ja seurantajärjestelmistä parantavat mahdollisuuksia soveltaa myös kattavampia ja luottamuksellisempaa tietoa sisältäviä laskentajärjestelmiä.

Very High Energy Gamma-Rays emitting BL LAC's Population Study

Context: BL Lacs are the most numerous extragalactic objects which are detected in Very High Energy (VHE) gamma-rays band. They are a subclass of blazars. Large flux variability amplitude, sometimes happens in very short time scale, is a common characteristic of them. Significant optical polarization is another main characteristics of BL Lacs. BL Lacs' spectra have a continuous and featureless Spectral Energy Distribution (SED) which have two peaks. Among 1442 BL Lacs in the Roma-BZB catalogue, only 51 are detected in VHE gamma-rays band. BL Lacs are most numerous (more than 50% of 514 objects) objects among the sources that are detected above 10 GeV by FERMI-LAT. Therefore, many BL Lacs are expected to be discovered in VHE gamma-rays band. However, due to the limitation on current and near future technology of Imaging Air Cherenkov Telescope, astronomers are forced to predict whether an object emits VHE gamma-rays or not. Some VHE gamma-ray prediction methods are already introduced but still are not confirmed. Cross band correlations are the building blocks of introducing VHE gamma-rays prediction method. Aims: We will attempt to investigate cross band correlations between flux energy density, luminosity and spectral index of the sample. Also, we will check whether recently discovered MAGIC J2001+435 is a typical BL Lac. Methods: We select a sample of 42 TeV BL Lacs and collect 20 of their properties within five energy bands from literature and Tuorla blazar monitoring program database. All of the data are synchronized to be comparable to each other. Finally, we choose 55 pair of datasets for cross band correlations finding and investigating whether there is any correlation between each pair. For MAGIC J2001+435 we analyze the publicly available SWIFT-XRT data, and use the still unpublished VHE gamma-rays data from MAGIC collaboration. The results are compared to the other sources of the sample. Results: Low state luminosity of multiple detected VHE gamma-rays is strongly correlated luminosities in all other bands. However, the high state does not show such strong correlations. VHE gamma-rays single detected sources have similar behaviour to the low state of multiple detected ones. Finally, MAGIC J2001+435 is a typical TeV BL Lac. However, for some of the properties this source is located at the edge of the whole sample (e.g. in terms of X-rays flux). Keywords: BL Lac(s), Population study, Correlations finding, Multi wavelengths analysis, VHE gamma-rays, gamma-rays, X-rays, Optical, Radio

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.

Espoon puhdistamolietteen käsittelymenetelmien selvitys Ämmässuon käsittelykeskukselle

Ravinteiden kierrätys yhä enemmän luonnonvaroja kuluttavassa yhteiskunnassa on noussut tärkeäksi. Hyötykäyttämällä luonnollisesti syntyvät orgaaniset virrat yhteiskunnasta voidaan kierrättää pellolta nostetut ravinteet takaisin. Tässä diplomityössä on tarkasteltu Helsingin seudun ympäristöpalveluiden toteuttamaa mädätetyn puhdistamolietteen käsittelyä ja pohdittu sen käsittelymahdollisuuksia erityisesti Ämmässuon käsittelykeskuksessa. Tarkastelussa on keskitytty kahteen yleisimpään kompostointimenetelmään, eli auma- ja tunnelikompostointiin. Kompostointimenetelmien tarkastelussa on pyritty löytämään optimaalinen tukiaine sekä prosessiaika käsiteltävälle lietteelle Ämmässuolla olemassa olleilla resursseilla. Tutkimuksessa toteutettiin käytännön pilot -kokeita sekä toteutettiin teoreettista prosessin parametrien laskentaa mukaan lukien kustannukset ja resurssit. Tutkimuksen perusteella voidaan todeta, että kyseisen tyyppisellä käsittelyalueella tunneli-kompostointi on näillä parametreilla testattuna paras vaihtoehto. Menetelmällä voidaan saavuttaa nopeampi käsittelyaika sekä vähentää kompostoinnista aiheutuvia hajuhaittoja ympäristöön. Tukiaineseoksessa voidaan korvata yleisestikin käytetty turve vastaanotettavalla lehti-puru viherjäteseoksella sekä risuhakkeella ja prosessiaika on noin 12 -16 viikkoa. Käsittelyn kustannukset verrattuna tämän hetkiseen käsittelyyn Metsäpirtissä eivät olleet merkittävästi suuremmat ja ympäristövaikutusarvioinnin perusteella syntypaikkaa lähellä oleva käsittelyalue sekä prosessin pienemmät vaikutukset tuovat ympäristöedun käsittelylle Ämmässuolla.

“He who plants a tree – Plants a hope.” Reforestation possibilities in Tingana, Peru

Tropical forests have decreased drastically especially in the Peruvian Amazon. In Peru deforestation is caused especially by migrant people; building of houses and infrastructure, clearing land for agricultural purposes and illegal logging and mining. Deforestation results in hindering ecosystem vitality, boosting climate change and decreasing livelihood possibilities. As a counterpoint to cutting down trees there is reforestation, which refers to re-establishment of forest cover. Deforestation and reforestation can be analysed in the light of Forest Transition theory. According to it, due to economic growth, the amount forest cover first diminishes but then starts to increase as the economy in general strengthens. Thus, the research framework is set to this theory. In this study the focus is on analysing socioeconomically sustainable reforestation possibilities in the community of Tingana, Peru. It is situated in a municipal conservation area around which deforestation has been heavy. Land cover change is analysed from LandsatTM satellite images covering a 15 year time period, 1995–2010, in the surroundings of the study area. Semi-structured interviews have been done with a sample size of 25 people and shed light on the perspectives on forests, reforestation and economical activities. The synthesis created from the two methods gives information about the possibilities to enforce reforestation in Tingana and the phase of forest transition in the area. The results show that forest cover has decreased around the surroundings of Tingana leaving the conservation area isolated from larger forest areas. Knowing that forest cover has also decreased inside the conservation area due to agricultural expansion it is certain that fragmentation harms biodiversity causing changes in local climate, which can have knock-on effects for farming and local livelihoods. Therefore reforestation is welcomed when it ensures both conservation and financial benefits and when carried out on locals’ terms. Regarding conservation and incomes the best option would be to plant native timber species together with fruit production species to create agroforestry systems. Economically the community should aim towards an economy that relies on ecotourism as it already practiced in the area. Reforestation could increase ecotourism, which then could in turn increase reforestation via revenues. Regarding forest transition it is likely that forest re-establishment will occur if reforestation along with ecotourism is implemented on long time scale.

Welding time models for cost calculations in the early stages of the design process

It is generally accepted that between 70 and 80% of manufacturing costs can be attributed to design. Nevertheless, it is difficult for the designer to estimate manufacturing costs accurately, especially when alternative constructions are compared at the conceptual design phase, because of the lack of cost information and appropriate tools. In general, previous reports concerning optimisation of a welded structure have used the mass of the product as the basis for the cost comparison. However, it can easily be shown using a simple example that the use of product mass as the sole manufacturing cost estimator is unsatisfactory. This study describes a method of formulating welding time models for cost calculation, and presents the results of the models for particular sections, based on typical costs in Finland. This was achieved by collecting information concerning welded products from different companies. The data included 71 different welded assemblies taken from the mechanical engineering and construction industries. The welded assemblies contained in total 1 589 welded parts, 4 257 separate welds, and a total welded length of 3 188 metres. The data were modelled for statistical calculations, and models of welding time were derived by using linear regression analysis. Themodels were tested by using appropriate statistical methods, and were found to be accurate. General welding time models have been developed, valid for welding in Finland, as well as specific, more accurate models for particular companies. The models are presented in such a form that they can be used easily by a designer, enabling the cost calculation to be automated.

Process intensification: From optimised flow patterns to microprocess technology

This thesis is focused on process intensification. Several significant problems and applications of this theme are covered. Process intensification is nowadays one of the most popular trends in chemical engineering and attempts have been made to develop a general, systematic methodology for intensification. This seems, however, to be very difficult, because intensified processes are often based on creativity and novel ideas. Monolith reactors and microreactors are successful examples of process intensification. They are usually multichannel devices in which a proper feed technique is important for creating even fluid distribution into the channels. Two different feed techniques were tested for monoliths. In the first technique a shower method was implemented by means of perforated plates. The second technique was a dispersion method using static mixers. Both techniques offered stable operation and uniform fluid distribution. The dispersion method enabled a wider operational range in terms of liquid superficial velocity. Using dispersion method, a volumetric gas-liquid mass transfer coefficient of 2 s-1 was reached. Flow patterns play a significant role in terms of the mixing performance of micromixers. Although the geometry of a T-mixer is simple, channel configurations and dimensions had a clear effect on mixing efficiency. The flow in the microchannel was laminar, but the formation of vortices promoted mixing in micro T-mixers. The generation of vortices was dependent on the channel dimensions, configurations and flow rate. Microreactors offer a high ratio of surface area to volume. Surface forces and interactions between fluids and surfaces are, therefore, often dominant factors. In certain cases, the interactions can be effectively utilised. Different wetting properties of solid materials (PTFE and stainless steel) were applied in the separation of immiscible liquid phases. A micro-scale plate coalescer with hydrophilic and hydrophobic surfaces was used for the continuous separation of organic and aqueous phases. Complete phase separation occurred in less than 20 seconds, whereas the separation time by settling exceeded 30 min. Fluid flows can be also intensified in suitable conditions. By adding certain additives into turbulent fluid flow, it was possible to reduce friction (drag) by 40 %. Drag reduction decreases frictional pressure drop in pipelines which leads to remarkable energy savings and decreases the size or number of pumping facilities required, e.g., in oil transport pipes. Process intensification enables operation often under more optimal conditions. The consequent cost savings from reduced use of raw materials and reduced waste lead to greater economic benefits in processing.

A study of combustion phenomena in circulating fluidized beds by developing and applying experimental and modelling methods for laboratory-scale reactors

The results shown in this thesis are based on selected publications of the 2000s decade. The work was carried out in several national and EC funded public research projects and in close cooperation with industrial partners. The main objective of the thesis was to study and quantify the most important phenomena of circulating fluidized bed combustors by developing and applying proper experimental and modelling methods using laboratory scale equipments. An understanding of the phenomena plays an essential role in the development of combustion and emission performance, and the availability and controls of CFB boilers. Experimental procedures to study fuel combustion behaviour under CFB conditions are presented in the thesis. Steady state and dynamic measurements under well controlled conditions were carried out to produce the data needed for the development of high efficiency, utility scale CFB technology. The importance of combustion control and furnace dynamics is emphasized when CFB boilers are scaled up with a once through steam cycle. Qualitative information on fuel combustion characteristics was obtained directly by comparing flue gas oxygen responses during the impulse change experiments with fuel feed. A one-dimensional, time dependent model was developed to analyse the measurement data Emission formation was studied combined with fuel combustion behaviour. Correlations were developed for NO, N2O, CO and char loading, as a function of temperature and oxygen concentration in the bed area. An online method to characterize char loading under CFB conditions was developed and validated with the pilot scale CFB tests. Finally, a new method to control air and fuel feeds in CFB combustion was introduced. The method is based on models and an analysis of the fluctuation of the flue gas oxygen concentration. The effect of high oxygen concentrations on fuel combustion behaviour was also studied to evaluate the potential of CFB boilers to apply oxygenfiring technology to CCS. In future studies, it will be necessary to go through the whole scale up chain from laboratory phenomena devices through pilot scale test rigs to large scale, commercial boilers in order to validate the applicability and scalability of the, results. This thesis shows the chain between the laboratory scale phenomena test rig (bench scale) and the CFB process test rig (pilot). CFB technology has been scaled up successfully from an industrial scale to a utility scale during the last decade. The work shown in the thesis, for its part, has supported the development by producing new detailed information on combustion under CFB conditions.

Feasibility study of submerged membrane bioreactor (MBR) as an alternative to conventional activated sludge process (CASP) for municipal wastewater treatment: A pilot scale study

The conventional activated sludge processes (CAS) for the treatment of municipal wastewater are going to be outdated gradually due to more stringent environmental protection laws and regulations. The Membrane bioreactors (MBRs) are the most promising modern technology widely accepted in the world of wastewater treatment due to their highly pronounced features such as high quality effluent, less foot print and working under high MLSS concentration. This research project was carried out to investigate the feasibility and effectiveness of MBR technology compare to the CAS process based on the scientific facts and results. The pilot scale MBR pilot plant was run for more than 150 days and the analysis results were evaluated. The prime focus of the project was to evaluate the correlation of permeate flux under different operating MLSS concentrations. The permeate flux was found almost constant regardless of variations in MLSS concentrations. The removal of micropollutant such as heavy metals, PCPPs, PFCs, steroidal hormones was also studied. The micropollutant removal performance of MBR process was found relatively effective than CAS process. Furthermore, the compatibility of submerged membranes within the bioreactor had truly reduced the process footprint.

Press forming of paperboard – advancement of converting tools and process control

Press forming is nowadays one of the most common industrial methods in use for producing deeper trays from paperboard. Demands for material properties like recyclability and sustainability have increased also in the packaging industry, but there are still limitations related to the formability of paperboard. A majority of recent studies have focused on material development, but the potential of the package manufacturing process can also be improved by the development of tooling and process control. In this study, advanced converting tools (die cutting tools and the press forming mould) are created for production scale paperboard tray manufacturing. Also monitoring methods that enable the production of paperboard trays with enhanced quality, and can be utilized in process control are developed. The principles for tray blank preparation, including creasing pattern and die cutting tool design are introduced. The mould heating arrangement and determination of mould clearance are investigated to improve the quality of the press formed trays. The effect of the spring back of the tray walls on the tray dimensions can be managed by adjusting the heat-related process parameters and estimating it at the mould design stage. This enables production speed optimization as the process parameters can be adjusted more freely. Real-time monitoring of pressing force by using multiple force sensors embedded in the mould structure can be utilized in the evaluation of material characteristics on a modified production machinery. Comprehensive process control can be achieved with a combination of measurement of the outer dimensions of the trays and pressing force monitoring. The control method enables detection of defects and tracking changes in the material properties. The optimized converting tools provide a basis for effective operation of the control system.

Real-time adaptive control of ultra-fast laser scribing process with spectrometer online monitoring

There exist several researches and applications about laser welding monitoring and parameter control but not a single one have been created for controlling of laser scribing processes. Laser scribing is considered to be very fast and accurate process and thus it would be necessary to develop accurate turning and monitoring system for such a process. This research focuses on finding out whether it would be possible to develop real-time adaptive control for ultra-fast laser scribing processes utilizing spectrometer online monitoring. The thesis accurately presents how control code for laser parameter tuning is developed using National Instrument's LabVIEW and how spectrometer is being utilized in online monitoring. Results are based on behavior of the control code and accuracy of the spectrometer monitoring when scribing different steel materials. Finally control code success is being evaluated and possible development ideas for future are presented.