The purpose of this study is to investigate the relationship of two significant concepts withinthe manufacturing industry. Namely, the widely popular Lean production and the arising Industry 4.0. The lack of a common framework concerning their relationship requires further exploration, as stated by several researchers. For companies to stay competitive within a changing market it is of importance to adapt to new technologies, indicating that the understanding of this relationship is essential, as Lean production is extensively used in industries today. To increase the understanding of the concepts and their relationship three research questions were formulated, as followed: RQ 1: How can Industry 4.0 support Lean production? RQ 2: How can Lean production support the implementation of industry 4.0? RQ 3: What are the challenges of implementing Industry 4.0 in Lean production? The study was conducted using qualitative research methods such as the narrative literature review and thematic analysis, allowing for the identification of themes and structuring of the study in a narrative approach. Second-hand data was collected through academic databases using search terms highly relevant to the research questions. The theoretical framework of the study provides a foundation for the understanding of the concepts. Whereas the results are centered around the relationship of Industry 4.0 and Lean production with themes relevant to the research questions and subthemes to follow. The analysis highlights important aspects of the results in relation to the theoretical framework, while also discovering insights connecting the research questions together. The conclusion presents aspects of how Industry 4.0 technologies can support Lean production through factors such as increased continuous improvement, support of people, improved JIT, Kanban, maintenance and communications. Where the general benefits will be productivity, quality and speed of introducing new products, adapting to high variability of market demand. Furthermore, describing how Lean production can support the implementation of Industry 4.0, as the degree of Lean maturity directly influences the efficiency of Industry 4.0 implementation. The employment of Lean principles such as continuous improvement, focus on people and standardization can result in a more effective implementation and utilization of Industry 4.0. Challenges of implementing Industry 4.0 in Lean production such as the risk of counterproductive implementation because of the lack of common framework, limitations of certain Lean practices, Lean professionals and ICT professionals limited knowledge of eachother's fields and the understanding of how to apply Industry 4.0 based on lean principles. Lastly, recommendations are offered for companies aspiring to implement Industry 4.0, as they should evaluate their current level of Lean maturity in order to understand when it is most efficient to incorporate the new technologies. Companies seeking to aid their Lean objectives should concentrate on technologies such as IoT and CPS as they seem to have the most positive impact on Lean. In addition, recommending further research regarding the relationship of Industry 4.0 readiness and Lean maturity, exploring which degree of Lean maturity to efficiently integrate and utilize certain Industry 4.0 technologies and when to implement certain Industry 4.0 technologies to aid the advancement of Lean maturity.

La manufactura peruana ha evidenciado una demanda creciente, especialmente para el rubro metalmecánico, debido a los proyectos de inversión anunciados en los próximos años. Cabe resaltar que, el sector metalmecánico es uno de los sectores productivos más importantes ya que impulsa y dinamiza la economía del país. Por esa razón, se hizo un análisis de la situación actual del sector y se identificó que las empresas metalmecánicas presentan problemas de eficiencia en sus procesos productivos y una baja disponibilidad de sus máquinas. Bajo ese contexto, se hizo una búsqueda en la literatura para identificar diferentes herramientas que puedan eliminar el problema en casos de estudio similares. Luego, se seleccionó un caso de estudio que refleje el problema que aqueja el sector para garantizar un impacto en el mercado. Se analizaron las causas raíz del problema y las pérdidas monetarias que le generaban a la empresa para luego proponer un modelo que permita mejorar la eficiencia de la compañía. Se implementó el modelo propuesto y se verificaron las mejoras respectivas. Finalmente, se realizó una evaluación económica para verificar la vialidad del proyecto, así como sus impactos tanto internos como externos de la empresa. En ese sentido, el propósito de la investigación es proporcionar un modelo de producción basado en herramientas Lean Manufacturing para eliminar el problema identificado en el sector aplicado en un caso de estudio. En la revisión de la literatura, se ha encontrado pocos artículos de investigación sobre empresas de este sector que se hayan desarrollado en Latinoamérica, especialmente en Perú. Por esa razón, el presente estudio contribuirá a la comunidad científica latina con un nuevo sistema de producción para las empresas metalmecánicas peruanas. / The current context of peruvian manufacturing has evidenced an increasing demand, especially for the metal-mechanical sector, due to the investment projects announced for this year and next. It should be noted that the metalworking sector is one of the most important productive sectors since it drives and energizes the country's economy. For this reason, an analysis was made of the current situation in the sector and it was identified that companies in this area have efficiency problems in their production processes and a low availability of their equipment on production lines. This would bring as a consequence an unsatisfied and unsatisfactory demand which leads to a lesser amount of monetary income for Peru. In this context, an exhaustive search was made in the literature to identify different tools that can eliminate the problem in similar study cases. Then, a case study was selected that reflects the problem faced by the sector to guarantee a relevant impact on the market. The root causes of the problem and the impact it had on the company were analyzed to then propose a model that would improve the company's efficiency. The proposed model was implemented, and the respective improvements were verified. Finally, an economic evaluation was carried out to verify the viability of the project, as well as its internal and external impacts on the company. In this sense, the purpose of the research is to provide a production model based on Lean Manufacturing tools to eliminate the problem identified in the sector applied in a case study. In the literature review, few research articles have been found on companies in this sector that have developed in Latin America, especially in Peru. For this reason, our research will contribute to the Latin scientific community with a new production system for peruvian metalworking companies. / Trabajo de Suficiencia Profesional

This thesis deals with the management of the production process, focusing on unproductive activities. It comprises analysis of the current situation in the company Teva Czech Industries s.r.o. (the TCI) and suggestions for improvement measures. The first chapter presents theoretical basis for processing work. PMT methods, namely MTM and MOST, lean production with a focus on 5S, TPM and Kaizen are described. The second chapter is focused on the company TCI, core business, organization structure and analyzes the current status. It’s focused primarily on the process of critical non-manufacturing operations and the changeover cleaning process. The third chapter, following the analytical part consists of the proposed recommendations. The fourth chapter deals with the final evaluation.

Presented thesis entitled “Process performance analysis” deals with problems in identification of the causes of the increasing cost and declining quality of the products, their minimization or complete removal. Further analysis will address the cost of low quality, serving as a basis for possible recovery of the fleet. All material presented in this thesis were collected in the company of NEVOGA, s r.o. engaged in manufacturing parts for the construction industry.

This diploma thesis deals with business process simplification. Basic terms like business or process are defined in the theoretical part of the thesis as well as selected methods of business management such as TPS, KAIZEN, 5S, Six Sigma, etc. The principal concept for this work is described in the second chapter. It’s very important to simplify things and work, which means to identify the essential parts and eliminate the rest (waste). The practical part describes company Kuličkové šrouby Kuřim, a.s. (KSK) and the study of individual processes and impacts upon them. Further on, several process simplifications from various parts of the company are presented. Each individual case is described and analysed.

El caso de estudio es una empresa productora y comercializadora de envases plásticos, mediante un diagnóstico de los tiempos de producción, se pudo identificar como principal problema la baja Disponibilidad de las máquinas inyectoras, obteniendo un valor de 80.19%. Se representa como un problema relevante, ya que el estándar de clase mundial es 90%. La baja disponibilidad se debe principalmente a las paradas de máquina, las cuales representan un 9.87% de costos perdidos para la empresa. Para la mejora de la disponibilidad de máquina, se planteó un modelo de mejora el cual integra principalmente la aplicación de herramientas de Lean Manufacturing con Kaizen, el cual hace referencia a la mejora continua de los procesos. El modelo también está integrado con conceptos de Ergonomía, los cuales permitirán la mejora de las condiciones de trabajo para los operarios. De manera que, si se logra mejoras respecto al capital humano, esto permitirá la mejora de la disponibilidad de máquina. Finalmente, luego de la implementación del modelo piloto en la empresa, se logró incrementar la disponibilidad de máquina en un 6.8%, la disminución de costos perdidos en un 3.9% e incremento de la utilidad de la empresa en un 13.12%. / The case study is a producer and marketer of plastic containers, through a diagnosis of production times, the low availability of injection machines was identified as the main problem, obtaining a value of 80.19%. It is represented as a relevant problem, as the world class standard is 90%. Low availability is mainly due to machine stoppages, which represent 9.87% of lost costs for the company. To improve machine availability, an improvement model was proposed which mainly integrates the application of Lean Manufacturing tools with Kaizen, which refers to the continuous improvement of processes. The model is also integrated with Ergonomics concepts, which will allow the improvement of working conditions for operators. So, if improvements are achieved with respect to human capital, this will allow the improvement of machine availability. Finally, after the implementation of the pilot model in the company, it was possible to increase the availability of the machine by 6.8%, the reduction of lost costs by 3.9% and an increase in the company's profit by 13.12%. / Trabajo de investigación

As a result of the globalization around the world, customer demands are increasing and competitors are growing, not least in the production industry. Due to this, companies are constantly forced to improve and develop their business in forms of both production and working environment. ********** is one of the worlds largest manufacturing companies, in the field of ventilation systems. The company has today identified problems with delivery times with their product ReCooler, which is a component in their ventilation system eQ Prime. The purpose of this report has been to examine the production flow for the ReCooler and identify the potential reasons to why the lead time is so long. Once the problem areas have been identified, improvement proposals have been developed with the goal of implementing these in the production. Further, in the future being able to reduce lead times and increase delivery precision towards customers. Many literature studies were reviewed, and the method of value stream mapping was considered appropriate for the purpose of the study. The value stream mapping generated one mapping of the current flow in the production and one of the desirable future flows. Thenceforth, a gap in between was found in which the improvement potential could be seen. By examining the gap and areas of improvement, various improvement proposals were developed. The main focus in the proposals was changing one part of the production flow, and manufacture rotors towards a warehouse instead of producing them on demand. The conclusion was to implement a supermarket, a production line and Kanban-cards. These improvement proposals would be resulting in shorter delivery lead times, production lead times and better delivery precision.     Keywords: Lean production, Kaizen, Value Stream Mapping, Production Flow.

Denna fallstudie har syftet att undersöka om befintliga metoder kananvändas för prototyptillverkande företag för att reducera ställtiderna. Detta utförs genom att först samla in data via intervjuer, observationer och dokumentinsamling. Därefter analyseras ställprocessen genom relevanta metoder och sammanställer förbättringsförslag för att undersöka vilka metoder som är lämpliga att använda. Studien visar tydligt att innan arbetet med ställtidsreducering kan påbörjas, måste arbetsplatsen och processerna standardiseras. Checklista och funktionskontroll bör utföras innan ett ställ påbörjas, vilket reducerar ställtiden. Maskinens inställning bör standardiseras enligt dokumentation från tidigare prototyper. Slutsatsen är att standardisering är viktig, trots den höga variationen i prototyptillverkning. Långa ställtider bör analyseras med SMED och förbättringar sammanställs i PICK-diagram för att sedan utföras en i taget genom PDCA-cykeln. Sådana förbättringar bör utföras tillsammans med den avdelning de berör för att alla skall kunna vara delaktiga i arbetet, samt att implementationen kan ske lättare. / This case study aims to investigate whether existing methods can be used within industrial companies that produce prototypes to reduce their setup times. This was done by first collecting data through interviews, observations and document collection. The setup process is then analyzed using relevant methods and improvement proposals are compiled to investigate which methods are suitable to use.The research clearly shows that before any work can be done with the setup reduction, the facility and its processes need to be standardized. A check list and function control can be prepared before the setup has begun, thus reducing the setup time. The settings of the machine should be standardized based on previously documented prototypes. In conclusion, standardization is vital, despite the high variation in prototype manufacturing. Long setup times should be analyzed with SMED and improvements are to be presented in a PICK-diagram and further implemented using a PDCA-cycle. These improvements should be done together with the department they are for, so everyone can be involved in the work and the implementation seamless.

Genom rapporten kommer kunskapen öka kring identifiering och reducering av flaskhalsar baserade på simuleringsverktyget Facts Analyzer och lean-verktyg. Den ökade kunskapen kommer generera möjligheter för företag att arbeta på ett strukturerat och effektivt vis genom en egenutvecklad arbetsmodell. Modellen kommer ge förutsättningar för företag att öka sin produktivitet och samtidigt reducera totala kostnaderna. Metoderna som arbetsmodellen bygger på är kvantitativ, kvalitativ, abduktion och förverkligas genom tillämpning på ett fallföretag där syftet är att undersöka applicerbarheten och ifall produktionen kan effektiviseras.  Med simuleringsverktyg skapas tydliga och fakta-baserade resultat på flaskhalsar och vad olika förbättringsalternativ har för påverkan på produktionen, därmed anses det vara ett bra verktyg att basera beslut på innan investeringar genomförs. Utifrån de identifierade flaskhalsarna, med hjälp av simuleringsverktyget, är det bevisat att lean-verktyg kan användas för att optimera produktion och reducera icke värdeskapande moment. Exempelvis visar resultatet att 5S, Kaizen, Poka Yoke, Total Productive Maintenance och Overall Equipment Efficiency är effektiva lean-verktyg.  För att öka produktionskapaciteten handlar det om att först identifiera flaskhalsarna genom simuleringsverktyget. Därefter beräknas flaskhalsens OEE-värde som skapar indikationer om begränsningarna och därmed belyser vart förbättringsförslag behövs. Genom indikationerna tillsammans med ytterligare lean-verktyg skapas därefter förbättringsförslag med fokus på att reducera flaskhalsen. För att däremot identifiera totalkostnadsreducering och icke värdeskapande aktiviteter används istället observationer och intervjuer med personalen. Därefter utvecklas förbättringsförslag, liksom för produktionskapaciteten, genom lean-verktyg för att minimera Muda. / Through the report, knowledge will increase regarding the identification and reduction ofbottlenecks based on the simulation tool Facts Analyzer and lean-tools. The increasedknowledge will generate opportunities for companies to work in a structured and efficientway through a own developed work model. The model will provide the conditions forcompanies to increase their productivity and at the same time reduce total costs. The methodson which the work model is based are quantitative, qualitative, abduction and are realized through a case company where the aim is to investigate the applicability and if productioncan be made more efficient. With simulation tools, clear and fact-based results are created on the effect differentimprovement options have on production, and thus it is considered a good tool to basedecisions on before investments are made. Based on the identified bottlenecks, with the helpof the simulation tool, it is proven that lean-tools can be used to optimize production andreduce non-value-creating activities. For example, the results show that 5S, Kaizen, PokaYoke, Total Productive Maintenance and Overall Equipment Efficiency are effectivelean-tools. To increase production capacity, it is a matter of first identifying the bottlenecks through thesimulation tool. The bottleneck's OEE value is then calculated, which creates indications ofthe limitations and thus highlights where improvement proposals are needed. Through theindications together with additional lean-tools, improvement proposals are then created with afocus on reducing the bottleneck. In contrast, to identify total cost reduction andnon-value-creating activities, observations and interviews with the staff are used instead.Improvement proposals are then developed, as for the production capacity, through lean-toolsto minimize Muda.

LEAX Falun är intresserad av möjligheten att införa ett taktat system för monteringsbanan A i en närmast framtid. I ett otaktat nuläge döljs problem på monteringsbanan och LEAX Falun vill veta om effekterna av ett taktat flöde. Målet med examensarbetet var att utvärdera och ta fram potentiella vinster med ett taktat flöde. I samband med det skulle även en simuleringsmodell för hur ett taktat flöde kan se ut tas fram samt de parametrarna som styr det taktade resultatet. Lösningsmetoder som tidtagningar, simulering, benchmarking, intervju och informationsinsamling har legat som grund till resultatet. Med hjälp av utvalda teorier samt resultatet som analyserades har examensarbetet visat att det är en långsiktig lönsamhet med ett taktat flöde. Monteringsbanan A kan klara en teoretisk takttid på tre minuter idag. De parametrarna som påverka det taktade flödet är takttid, flexibilitet mellan operatörer, Andonpersonal, visualisering, produktionsplanering samt ledarskap. Simuleringsmodellen är förenklad och visar hur ett taktat flöde med tre minuters takttid kan se ut. De huvudsakliga potentiella vinsterna med ett taktat flöde har identifierats som utjämning av produktion, synliggöra avvikelser till ytan för minskning av slöseri samt en bättre balansering av arbetsinnehåll och resurser. För att en implementering av ett taktat system ska fungera ställs det stora krav på ledarskap att aktivt engagera och motivera medarbetarna och sänder ut Lean budskap. / LEAX Falun are interested in the possibility of introducing a takt flow system on the assembly line A soon. In the current situation where the assembly process occurs without a continuous flow, some problems remains unseen. Therefore, LEAX Falun want to know the effects of a takt flow system. The aim of the thesis was to evaluate and present potential benefits with a takt flow system. In conjunction with that, a simulation model will be presented to show how a takt flow system looks like. An analysis of which parameters would have an impact on the takt time will also be presented. Methods such as timing, simulation, benchmarking, interviewing and information gathering have contributed crucial information for the results and conclusion part. With the help of selected theories and the analyzed results, the thesis has shown that it is a long-term profitability investment with a takt flow system. The assembly line A has shown that it can run at a theoretical takt time of three minutes but in reality, some parameters must be taken into consideration such as flexibility between operators, Andon-crew, visualization, production plan and the leadership of the organization. The simulation model is simplified and demonstrates how a takt flow system with a takt time can look like. The key benefits of a takt flow system with a takt time have been identified as continuous flow of production, easier to detect problems for waste reduction and a better balance of workload and resource usage. For a takt time system to be successful, the leadership plays an important role. They must actively make employees feel involved and motivated and constantly sending out Lean messages