Lean-Methoden zur Optimierung der Materialbereitstellung als Voraussetzung für den wirtschaftlichen FTS-Einsatz

Abstract

This master’s thesis examines the optimization of material provisioning in manufacturing companies as a key prerequisite for the cost-effective deployment of automated guided vehicles (AGVs). The point of departure is the ongoing automation and digitalization of industry, which impose high demands on the efficiency, flexibility, and stability of internal material flows. In particular, the simultaneous supply of multiple production lines with different materials at irregular intervals often leads to bottlenecks, delays, and additional workload. Conventional transport solutions such as forklifts are flexible but labor-intensive and errorprone. AGVs, by contrast, offer substantial automation potential but require stable processes and clear structures to realize their advantages. This motivates the thesis: combining lean methods and AGVs to make material provisioning more reliable, more efficient, and more cost-effective. The thesis is structured as follows. It first presents the technical fundamentals, system components, and economic aspects of AGVs and highlights differences compared with conventional transport means. An analysis of core lean methods then follows, including 5S, the spaghetti diagram, and the identification of the waste types Muda, Mura, and Muri. These lean methods are examined with regard to their potential to support AGV implementation. The methodological approach is based on a systematic review of scholarly literature in academic databases. The analysis draws on studies that compare material provisioning scenarios with and without AGVs. Both technical and organizational factors are incorporated. The findings indicate that AGVs are economically viable only to a limited extent without accompanying process improvements. Key obstacles include limited flexibility and high investment costs. Consistent application of lean methods can create process stability, reduce waste, and standardize material flows. This, in turn, allows the strengths of AGVs—automation, safety, and a reduced burden on personnel—to come to the fore. The results show that, in particular, 5S and spaghetti diagrams are valuable instruments for structuring material provisioning and minimizing disruptions. Consequently, the availability of materials at production lines can be significantly increased and the economic viability of AGV implementations improved. Overall, the thesis concludes that the close integration of lean methods and AGVs is crucial for establishing modern, efficient, and future-proof material supply systems in production.

Date of Award	2025
Original language	German (Austria)
Supervisor	Herbert Jodlbauer (Supervisor)