Optimering av produktionsflöde i modultillverkning : En fallstudie vid Part Construction i Kalix

Sammanfattning

This thesis aims to analyze and optimize the production flow of prefabricated bathroom modules at Part Construction in Kalix. The focus is on identifying bottlenecks, optimizing buffer inventories, and improving throughput time and product quality. The study connects practical data collection to theories in Lean Production, Theory of Constraints, Zero Defects, and bottleneck analysis. The research was conducted as a case study with an abductive approach, using both qualitative and quantitative methods. Data were collected through interviews, observations of the production flow, and measurements of cycle times and buffer levels. The study focused on the wall line, pre-assembly, and assembly stations within the production process. Results show that nailing constitutes the primary bottleneck, with the water cutter as a secondary bottleneck due to longer cycle times and unplanned stoppages. Buffer stocks protect downstream processes, but some stations have either excessive or insufficient buffers. Late detection of defects increases work-in-progress and reduces efficiency, conflicting with the Zero Defects principle. The study also shows that transitioning from two straight production lines to a U-shaped layout does not necessarily increase lead times; with proper conditions and implementation, lead times can be reduced.