Pilot production and manufacturing start-up: The case of Volvo S80

Abstract

This paper is based on the experiences of the Volvo Car Corporation and examines pilot production and manufacturing start-up- processes that are here combined under the rubric final verification of product and production system. The purpose of the paper is to discuss results from the pilot production and the manufacturing start-up of the Volvo S80 model in order to contribute to an understanding of how the process of ramping up production capacity and improving quality is affected by various types of disturbances - disturbances that affect final verification throughput time and efficiency. In addition, drawing on the results of the case study, the paper contributes a framework of concepts for studying and analysing the final verification processes. A case study methodology was employed, using a combination of quantitative and qualitative methods for data collection and analysis. The results show that disturbances that affect performance during the final verification are felt in four areas (materials supply, machinery/equipment, personnel and product concept). It is proposed that, in order to succeed with a rapid and efficient start-up, that production organizations should focus on identifying the sources of disturbances, as early as possible during pilot production, in order to gain control of these during start-up. The means for gaining improved disturbance control is to apply certain principles for designing, planning and controlling the pilot production and the manufacturing start-up phase.