Intralogistics plays a critical role in manufacturing performance and sustainability, yet internal logistics operations are often characterized by limited visibility, fragmented data, and experience-based planning. While work study methodologies are well established in production and assembly environments, their application to intralogistics activities remains limited in both industrial practice and academic research. This gap becomes particularly critical in manufacturing plants with fluctuating production volumes, where logistics capacity must continuously adapt to changing demand. This thesis addresses this gap by developing and applying a standardized work study methodology specifically tailored to intralogistics operations. The proposed approach integrates method study, time measurement, and structured data management through a revised Plan for Every Part (PFEP), enabling a transparent and quantitative representation of internal material flows and logistics tasks. The methodology is designed not only to analyze the current state but also to support planning and what-if evaluations based on production plans. The approach was piloted at the CNH Industrial manufacturing plant in Harbin, China, selected for its operational complexity and variability. The application enabled the systematic mapping of intralogistics processes, the definition of standard times, and the identification of Non–Value Added Activities such as unnecessary movements, repeated handling, manual repacking, and inefficient internal transport. The results demonstrate how the proposed framework supports more accurate workforce and resource planning, while simultaneously enabling sustainability improvements through reduced energy consumption, material waste, and emissions. Overall, the study shows that a structured work study approach can be effectively adapted to intralogistics operations, providing a practical, scalable, and data-driven foundation for improving efficiency, supporting sustainability objectives, and enabling future Logistics 4.0 developments in manufacturing plants.
A Systematic Work Study Approach to Improve Intralogistics Sustainability in CNH Industrial Manufacturing Operations
VITALI, VALERIO
2024/2025
Abstract
Intralogistics plays a critical role in manufacturing performance and sustainability, yet internal logistics operations are often characterized by limited visibility, fragmented data, and experience-based planning. While work study methodologies are well established in production and assembly environments, their application to intralogistics activities remains limited in both industrial practice and academic research. This gap becomes particularly critical in manufacturing plants with fluctuating production volumes, where logistics capacity must continuously adapt to changing demand. This thesis addresses this gap by developing and applying a standardized work study methodology specifically tailored to intralogistics operations. The proposed approach integrates method study, time measurement, and structured data management through a revised Plan for Every Part (PFEP), enabling a transparent and quantitative representation of internal material flows and logistics tasks. The methodology is designed not only to analyze the current state but also to support planning and what-if evaluations based on production plans. The approach was piloted at the CNH Industrial manufacturing plant in Harbin, China, selected for its operational complexity and variability. The application enabled the systematic mapping of intralogistics processes, the definition of standard times, and the identification of Non–Value Added Activities such as unnecessary movements, repeated handling, manual repacking, and inefficient internal transport. The results demonstrate how the proposed framework supports more accurate workforce and resource planning, while simultaneously enabling sustainability improvements through reduced energy consumption, material waste, and emissions. Overall, the study shows that a structured work study approach can be effectively adapted to intralogistics operations, providing a practical, scalable, and data-driven foundation for improving efficiency, supporting sustainability objectives, and enabling future Logistics 4.0 developments in manufacturing plants.| File | Dimensione | Formato | |
|---|---|---|---|
|
Vitali.Valerio.pdf
Accesso riservato
Dimensione
14.85 MB
Formato
Adobe PDF
|
14.85 MB | Adobe PDF |
I documenti in UNITESI sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
https://hdl.handle.net/20.500.14251/4601