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  • 1.
    Aco, Dekan
    Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
    Tillverkningsekonomisk utvärdering av återvinning och återanvändning av blyfri mässing2018Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    This master thesis is part of a larger project (Evochip), conducted at Lund University, faculty of engineering, Industrial Production Department (iProd). The project is in collaboration with AB Markaryds metallarmatur and Mistra innovation. In this work, a dynamic cost model has been developed to calculate the manufacturing costs of components made from recycled chips of lead-free brass from the manufacturing processes of AB Markaryds metallarmatur (MMA).

    In the current situation, all rejected details and waste materials are sent to the material supplier in southern Europe for recycling. The transport takes place by trucks and the recycling process is based on an energy-intensive melting step. Development projects are currently underway to reuse the chips without melting at sight at MMA´s facilities, but the cost per detail has been unknown for the company. With the help of this thesis, the manufacturing price will be presented. The manufacturing process is divided into a total of 11 different processing stations. To estimate the costs, Jan-Eric Ståhl's dynamic cost model is used. Necessary data and information have been collected using interviews with the employees of the company and through the company's own documentation regarding the production lines. In order to reduce the error margin in the results, suitable Monte Carlo simulations have been performed.

    The work is also based on a sustainability perspective. In addition to eliminating transportations by trucks and energy-intensive melting processes for the products, the work also promotes the use and reuse of lead-free brass by pressing metal chips to form new bars. All this in order to avoid leaded brass components due to the negative health effects caused by the lead.

    The component investigated in this work is a radiator valve called EVO 10. The valve is found in the company's lead-free standard range. The cost model in this project is dynamic to the extent that it could be applied in the future to other lead-free brass components at MMA.

    A comparison of two different concepts is presented in the results section. Concept one represents the current manufacturing system, and concept two, the future compacting technology. Since many of the processing steps are the same for both systems, a comparison was made between the productions of the pellet through the two different concepts. The results show that pellets made according to today's manufacturing system cost 12.75 SEK / detail, and pellets manufactured according to concept two costs 9.61 SEK / detail.

    As concept two is dependent on chips from today's manufacturing system, MMA cannot completely switch to compacting chips to new pellets. More work must be done to find a balanced model between the two different manufacturing systems for the best possible results.The results from the Monte Carlo-simulations shows that the manufacturing cost with the chosen parameters and variables is 12.96 SEK/detail.

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