Production management related information processes in global component factories

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Helsinki University of Technology | Diplomityö
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The current ERP system in the company studied does not fully meet the requirements of manufacturing, because the key focus area in the system and process development has not been at the shop floor level. The process maps do not match the real processes in the production. The objective of this thesis is to identify and document the current processes on the shop floor level, focusing on the information flows and sources. Based on process analysis, the most significant problems are identified and improvement ideas are given at a general level. The method of research is interview study. Research was also conducted at the Shanghai component factory in China, where the focus was on the differences and similarities of the processes. The main issue found in the research was the insufficient follow-up of production, which results in inaccuracies in the routing time information and causes unproductive work, as the status of work orders is not available in the ERP system. Generally, the ERP system is used reasonably well as an information source but very little for reporting and information storage purposes. The processes in the Chinese component factory differ somewhat from those of the factories in Helsinki, mainly due to the lower skill levels of the workers. The system of production reporting was introduced to increase the quality and accuracy of work order status information. The reporting of machining processes should be broken up to more steps than that of assembly functions, because of the greater number of routing steps per item and higher capacity utilisation requirements. A reference visit to a company that manufactures electric motors was also conducted to get an example of production reporting. Better production follow-up information makes it possible to control production more efficiently, and at the same time, increases control over inventory levels.
Aaltonen, Kalevi
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Lunkka, Juha
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