Process analysis and improvments for production of engineered wood structures in an engineer-to-order system

Authors: Ghiyasinasab, Marzieh
Advisor: Lehoux, NadiaMénard, Sylvain
Abstract: Increasing the share of wood in non-residential construction is an important goal in countries with major forest and engineered wood products. In order to facilitate the production of innovative timber structures, procedures should be re-engineered in terms of market analysis and productivity improvement. The main objective of this thesis is to facilitate the production of engineered wood to be used in innovative wood structures such as timber gridshell. To achieve this goal, three specific objectives are defined. The first objective is to determine production phases and market opportunities for the production of timber gridshell. In this regard, a review of the academic and grey literature was conducted, and twenty samples were identified and analysed by making process charts and categorisations. The results showed that gridshell is used in the construction industry in Europe and is less recognised in North America, which provides a market opportunity for its production and construction. The categorisation of studied samples in small, medium and large structures provides an overview for the companies who consider the production of this structure. The second objective of this thesis is to provide a simulation model for the production of glued laminated timber in small factories and the process of applying lean techniques to make improvements. In this regard, the production system of a Small and medium-sized enterprise (SME) was analysed, and a simulation model was created. In order to eliminate each source of waste, a lean tool was suggested according to the reality of the system under investigation. The lean methods were applied in the simulation model to analyse the potential improvements. Results showed a noticeable improvement in waiting and cycle time. It also showed that applying even 50% elimination of the wastes is also a considerable solution to improve productivity as a beginning step for SMEs. The third objective is to provide a production planning and scheduling tool in the context of multi-project engineer-to-order production of glued laminated timber. In this regard, optimisation models were created. The first model (model 1) concerns the minimisation of total production cost while model 2 aims to minimise projects’ makespan. Model 3 introduces the set-up time reduction and model 4 integrates the three objectives of minimising cost, makespan and set-up time. Two scenarios of adding complex and medium projects were designed and tested. Testing the scenarios showed that there is enough capacity for adding one complex project or nine medium projects without the need to outsource. Adding a complex project is more sensitive to the insertion period and beginning the project in different weeks leads to different results in terms of the overtime requirement. As a result, the work of this thesis provides decision support tools for engineer-to-order environments which could help SMEs to improve their productivity and standardisation.
Document Type: Thèse de doctorat
Issue Date: 2019
Open Access Date: 19 September 2019
Grantor: Université Laval
Collection:Thèses et mémoires

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