Epsilon Archive for Student Projects

Abstract

At Scania's engine manufacturing in Södertälje, manufacturing processes are used for designing and machining engine components. In the manufacturing of these engine components, residual products are formed such as millings, wastewater and residual emulsion. Scania's internal goal is to reduce the amount of non-recyclable waste by 25% from 2015 to 2020. Engine manufacturing aims to handle all wastewater and residual emulsion at Scania's internal waste management facility "by 2018". The thesis examined technical possibilities of reducing the amount of residual products from the engine manufacturing, as well as investigating the potential for improvement of residual product management. Qualitative and quantitative methods, such as interviews and data processing of waste statistics have been used in the study. A solution proposal has been developed for reducing and managing millings from the production. For reduction and management of wastewater and residual emulsion, four different solutions have been developed. The solution proposals have been analyzed based of economic profitability, waste reduction and applicability. For the reduction and managing of millings, the most qualified technique was briquetting. The study shows that the amount of millings produced at the crankshaft department can be reduced by 100% and to invest in a briquetting system is financially profitable after 2,3 years if the briquettes are recycled internally at Scania. For wastewater and residual emulsion management, there is a potential for improvement at the engine manufacturing to reduce external handling. Effciency enhancement and development of processes and working methods for engine manufacturing is a cost-effective solution to improve the management of residual products. The investigation shows that investing in a buffer system is an effective solution for improving the management of wastewater and residual emulsion, with regard to a more leveled waste flow. The two solutions are both economically profitable and environmentally beneficial in the form of less external handling. Engine manufacturing has the opportunity to reduce the amount of wastewater by investing in staff for the maintenance and control of washing machines. The investigation also shows that the amount of wastewater could be further reduced by investing in measuring and monitoring systems for the final washers. The two solutions will generate an economic profit in the form of improved cleanliness of the engine components, reduced amount of wastewater, as well as fewer external handlings.