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Optimizing Production Capacity of Royal Bel Leerdammer Cheese Manufacturing B.V.

Bovenmars, Tijmen (2019) Optimizing Production Capacity of Royal Bel Leerdammer Cheese Manufacturing B.V. Design Project, Industrial Engineering and Management.

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Abstract

This paper describes a plan to improve the efficiency of the mould handling circuit of the Royal Bel Leerdammer Cheese manufacturing plant in Dalfsen, in order to increase the maximum production capacity. To keep a competitive advantage in the manufacturing of one of the oldest known products: cheese. Throughout the ages the process of cheese manufacturing developed substantively. Manufacturing plants therefore need to continuously optimize their, sometimes outdated, facilities. One way to optimize a system is assembly line balancing. Many papers can be found in this field, however surveys addressing real practical problems are still scarce. This research could help close the gap between theories and real practical problems. The used DMAIC method (comparable with the regulative cycle) proves to be an useful method in this research. To analyze the system and to validate possible improvements, the mould handling circuit is recreated in Tecnomatix plant simulation 13.1. This simulation provides insights in some of the problems observed in the real system. Especially problems related to variations in the availability of ’supplement equipment’ (moulds and lids). Other results show variations in processing speed of different machines in the mould handling circuit. Some machines operate more than 30% of the time below the desired lower boundary. All the variations in the system influence each other, mostly in a negative way. Partly as a result of these variations, 9,777 minutes of short stops occurred in this system, in 2018. This amount of short stops is equal to an amount of cheese above 900 tons. In 2018 the system produced an average of 8.13 cheeses per minute, while the system was able to produce on average 8.19 cheeses per minute. Recommended improvements (as for instance a standardized amount of moulds and lids in the system, enabling more moulds in front of the moulding machine by adding one stopper and replacing a sensor, adding a lid-buffering machine, and adding stoppers and an ensured chain in front of the presses) have the potential to increase the average production output and decrease the downtime of the system. All in all compared with 2018, a production output of 40,801 tons of cheese could be achieved, with an investment of €118,000. With these improvements, Royal Bel Leerdammer could save €280,175.

Item Type: Thesis (Design Project)
Supervisor:
Supervisor nameSupervisor E mail
Kloosterman, H.H.Kloosterman@rug.nl
Degree programme: Industrial Engineering and Management
Thesis type: Design Project
Language: English
Date Deposited: 20 Mar 2019
Last Modified: 22 Mar 2019 13:54
URI: http://fse.studenttheses.ub.rug.nl/id/eprint/19286

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