Integration ausgewählter Lean-Methoden zur Effizienzsteigerung in der Fließfertigung für geländegängige Nutzfahrzeuge

Abstract

This study examines how selected lean methods increase the efficiency of highly variable flow production for off-road commercial vehicles. The starting point is chassis/track pre-assembly with heavy assemblies, a high variety of parts, and unstable processes. The goal is to develop a practical target scenario with stable cycles, reduced non-productive times, and robust material provision— considering ergonomic and quality-related requirements. Methodologically, a multi-stage approach is used: (1) Diagnosis of waste using value stream analysis, Gemba, spaghetti diagrams, and Pareto. (2) Derivation of a set of measures based on lean principles (JIT/Jidoka) with PDCA loops, 5 Whys, and Ishikawa for root cause analysis. (3) Design of the target layout, including line balancing, Heijunka, and standardized material supply. Key measures include upside-down delivery of the chassis to reduce crane handling, a new assembly transport platform with integrated turning function, poka-yoke at the rotary union, a newly tailored line balancing with seven stations, and visual standardization. In addition, 5S, setup time reduction (SMED), and smoothed sequence planning are used. The implementation shows clear effects: more stable cycles, reduced crane and transport times, shorter setup and search times, more compact layouts, and a more robust quality and ergonomics status. Capacity and predictability are increasing with the same or targeted use of personnel. The outlook addresses stabilization via a key performance indicator system and the scaling of the target image to other product platforms. This work thus makes a practical contribution to the design of efficient flow production in an environment for off-road commercial vehicles.

Date of Award	2025
Original language	German (Austria)
Supervisor	Roland Braune (Supervisor)