National Centre for Nano-Structured Materials (NCNSM), one of the National Department of Science and Technology’s nanotech innovation centres houses a characterisation facility which provides a wide array of high-tech materials characterization techniques used in nanotechnology research, to any researchers from any part of South Africa, whether from higher education institutions, government institutions or private firms. In this study the operational review was conducted to identify if the NCNSM Characterisation Facility is delivering on its implementation intent. With operational review organisations are able to explore their internal operations and seek recommendations as to how they can manage and operate more economically, efficiently and effectively. Given that they perform appropriately, allocating their resources properly, and performing within time frame set and using cost-effective measures. BPR was used as a framework to conduct the operational review. BPR is a framework for analysis and design of workflows and process within an organisation. It is an improvement initiative that provides radical change of the business processes in an organizational process. The findings of this study indicated that the NCNSM-CF did not entirely meet its implementation intent but it is striving towards the intention. One of the main reasons for the facility not to meet its intended implementation was the difficulty of the researchers/clients to get access to the facility. The current booking system process contributed significantly to the access problem.

This thesis is focused on the suggestions for the application of maintenance department optimization concept -- Total productive maintenance, in the context of wider concept of lean manufacturing, in the BAEST company. The content of the thesis is to get acquainted with the theoretical background of the lean manufacturing and maintenance, analysis of the current state at the company's maintenance department reflecting the described theoretical background, identification of the potential for improvements by comparing the current state with the theoretically ideal state and coming up with individual recommendations for improvements of the maintenance department in order to make it better and more effective and efficient.

This Master's Thesis focuses on the analysis of the production process of fireplace insert -- chosen product of the company FLAMEN. The goal of this thesis is to analyze the production process of fireplace insert and give recommendations for improvement using Lean Tools. The company FLAMEN is new on the market and has no experience with Lean Manufacturing principles or techniques. The thesis focuses on initial implementation of Lean Manufacturing philosophy into the company. The theoretical basis of Lean Manufacturing, Process mapping and particular Lean Tools are described in the thesis. Further the production process of fireplace insert is analyzed and possible improvements are suggested. These suggestions should lead to initial implementation of Lean Production philosophy in the company FLAMEN.

Orientador: Eugênio José Zoqui / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-18T11:01:11Z (GMT). No. of bitstreams: 1 Silva_FabioLuisRamosda_M.pdf: 3532055 bytes, checksum: 4ce71c2b86cba55a9d6fd04186ab4f6a (MD5) Previous issue date: 2011 / Resumo: Mais do que em qualquer indústria, a necessidade de resposta rápida à demanda, flexibilidade para adequação ao mix de produção e confiabilidade nas operações são condições fundamentais em condomínios industriais para se manter um bom nível de atendimento ao cliente. Dentro desse contexto, com estoques reduzidos e lead time muito baixo, o desempenho do fornecedor passa a ser muito mais vulnerável às incertezas do chão de fábrica, incluindo aqui os possíveis problemas na logística. Este trabalho apresenta a aplicação do projeto axiomático no projeto de um sistema de logística interna em um condomínio industrial, estruturando seus requisitos, bem como as soluções para cada um destes requisitos. Estão descritas as soluções aplicadas em um caso real, com foco na movimentação interna do fornecedor, na armazenagem, na programação puxada da produção e na movimentação de materiais para entregas diretas na linha de montagem do cliente. Os indicadores de desempenho medidos pela montadora comprovam o sucesso da abordagem e do projeto definido e implementado pelo autor e sua equipe. A aplicação de conceitos de manufatura enxuta guiam este desenvolvimento / Abstract: The need of rapid response to demand, flexibility to adjust to the mix variation e reliability in the operations become decisive when dealing with an Industrial Condominium in order to obtain a good delivery performance to the client. In a scenario of extremely low inventory and lead time, the performance of a supplier is considerably vulnerable to uncertainties of the shop floor, including here logistics issues. This thesis presents the application the axiomatic design to develop and implement an Internal Logistics System in an "Industrial Condominium", deploying each requirement and also the solutions to meet each requirement. It is presented solutions applied to a real case that focuses on the supplier internal logistics, storage systems, pulled production programming and direct line feeding. Key Performance Indicators measured by the car assembler provide a trustworthy success evidence for the final project and its implementation done by the author and his team. Lean Manufacturing concepts guide this development / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

In general, industries, mainly the big or medium ones, had already come across situations typically a result from being an overly productive company, meaning that they produce more than clients can absorb or in a rhythm above the required. They also are exposed to related situations such as deviation or distortion of production information, disorder of the factory floor and several other day-by-day problems. Such problems cause losses to the company, as they do not add value, because they do not really transform raw materials, thus modifying the form or the quality of the product. This study presents the benefits of employing the Lean Manufacturing concepts for the implementation of a new productive division, acting in corrective and preventive ways, thus contributing to waste reduction, with as reference the Toyota Production System, allied to the studied companys own lean system. Practical methods for the elimination of waste potentials found in productive environments are also demonstrated through the results achieved, as well as the difference between the conventional manufacturing system which still is used by several companies, compared to those companies which adopted Lean Manufacturing as a working standard. This study focalizes the steps used for the implementation and the benefits achieved by the application of the principles of this philosophy. / De uma maneira geral, as indústrias, principalmente as de grande e médio porte, já depararam com situações típicas advindas de uma empresa que tem superprodução, ou seja, produzem mais do que o requerido pela demanda dos clientes ou em um ritmo acima do necessário. Estão sujeitas também a situações complementares, como o desvio ou a distorção de informações na produção, a desorganização no chão de fábrica, entre outros inúmeros problemas do dia-a-dia. Tais problemas acarretam perda para a empresa, uma vez que essas operações não agregam valor, pois não estão realmente transformando a matéria-prima, modificando a forma ou a qualidade do produto. Este trabalho apresenta os benefícios provenientes da utilização dos conceitos de Manufatura Enxuta na implementação de uma nova divisão produtiva, que atua de forma corretiva e preventiva, de forma a contribuir para a redução de desperdício, tendo como referência o Sistema Toyota de Produção, aliado ao próprio sistema enxuto da empresa estudada. Demonstram-se, ainda, métodos práticos para a eliminação de potenciais desperdícios encontrados em meios produtivos, por meio dos resultados alcançados, e a diferença entre o sistema de manufatura convencional, o qual ainda é utilizado por diversas empresas, e o sistema daquelas empresas que adotaram a Manufatura Enxuta como padrão de trabalho. Este trabalho focaliza os passos utilizados para a implementação e os benefícios alcançados com a utilização dos princípios dessa filosofia.

The present work had as objective evaluate results from Lean Manufacturing implementation, that in General Motors is called Global Manufacturing System, at S-10 model production plant, located in the city of São José dos Campos São Paulo. Using a set of indicators integrated to the Business Plan of the Company it was evidenced the impact generated for the implementation of the Lean concepts in the production system. The assessment made considered the results from indicators before and after the implementation of Lean Manufacturing in the refereed line of production. By means of the reached results it was also proved that the implementation of Lean Manufacturing concepts in plants considered old (Brownfield) is not only possible as also can bring advantageous results for the organization that adopts them. With the automobile market each time more competitive, as much in Brazil as in the world, the necessity of having product and competitive price come stimulating several assembly plants to invest in this system. This because such system favors the improvement of quality and productivity levels with direct reflects on production costs reduction, among others benefits. The reached results had demonstrated clearly that Lean Manufacturing process implemented brought an expressive improvement at production, evidenced for the wide positive evolution of almost all indicators used, related to quality, productivity, safe and costs. Is also distinguished the high level of involvement from collaborators with the adoption of Lean Manufacturing, demonstrated by the results obtained with the indicator of verification from the human resources level of usage at implementation process. / O presente trabalho teve como objetivo avaliar resultados da implementação do Lean Manufacturing, que na General Motors se denominou Sistema Global de Manufatura, na planta de produção do modelo S-10, localizada no município de São José dos Campos São Paulo. Utilizando um conjunto de indicadores integrados ao Plano de Negócios da Empresa, evidenciou-se o impacto gerado pela implantação dos conceitos Lean no sistema de produção. A avaliação realizada considerou os resultados dos indicadores antes e após a implementação da Manufatura Enxuta na referida linha de produção. Por meio dos resultados alcançados, evidenciou-se também que a implementação dos conceitos de Manufatura Enxuta em plantas consideradas antigas (Brownfield) não somente é possível como também pode trazer resultados vantajosos para a organização que os adota. Com o mercado automobilístico cada vez mais concorrido, tanto no Brasil como no mundo, a necessidade de se ter qualidade do produto e preço competitivo vem estimulando diversas montadoras a investirem neste sistema. Isto porque tal sistema favorece a melhoria dos níveis de qualidade e produtividade, com reflexos diretos sobre a redução dos custos de produção, entre outros benefícios. Os resultados alcançados demonstraram claramente que o processo de Manufatura Enxuta implementado trouxe uma melhoria expressiva na produção, evidenciada pela evolução largamente positiva de quase todos os indicadores utilizados, relacionados à qualidade, produtividade, segurança e custos. Destaca-se também o alto grau de comprometimento dos colaboradores com a adoção da Manufatura Enxuta, demonstrado pelos resultados obtidos com o indicador de verificação do nível de utilização de recursos humanos no processo de implementação.

A necessidade de melhorar a competitividade e de atingir metas e objetivos, dentro de uma empresa, faz com que estudos como este sejam, cada vez mais úteis. A eliminação de desperdícios é uma das principais atividades que contribuem para alcançar melhores resultados, pois além de proporcionar a redução no custo total de fabricação de peças e dos serviços prestados, eliminam também, atividades que não agregam valor ao produto, atividades estas, que os consumidores não estão dispostos a pagar. Nesse contexto, o presente trabalho tem como objetivo demonstrar um estudo real da implantação de técnicas da Teoria das Restrições TOC, aliado a utilização da Mentalidade Enxuta Lean Manufacturing, como ferramentas para eliminação de desperdícios, aumento da produtividade e estabilidade do processo no departamento de Carrocerias de uma indústria automobilística. Num primeiro momento foi analisado o processo produtivo como: os índices da Eficiência Global dos Equipamentos (OEE), balanceamento de cargas de trabalhos e o layout fabril, onde se pode observar várias oportunidades de melhorias como: identificação dos gargalos que restringiam o fluxo produtivo; redução dos lotes de produção em processo; redução do takt time; alterações de layout e aumento da produtividade. A partir daí, foi possível aplicar ações para melhoria do desempenho do processo produtivo, tanto na implementação das ferramentas, como na melhoria contínua. Os resultados obtidos evidenciaram que a correta utilização das técnicas da Teoria das Restrições integradas aos conceitos do Lean Manufacturing, podem gerar ganhos substanciais em competitividade, inclusive com a superação das metas da organização, conforme foi verificado no presente estudo. / The need to improve competitiveness and achieve goals and objectives within a company, makes studies like this are increasingly useful. Waste disposal is one of the main activities that contribute to achieving better results, as well as providing a reduction in the total cost of manufacturing parts and services, also eliminate activities that do not add value to the product, these activities, which consumers are unwilling to pay. In this context, this paper aims to demonstrate an actual study deployment techniques Theory of Constraints `TOC, combined with the use of Lean Thinking `Lean Manufacturing as tools to eliminate waste, increase productivity and process stability Bodies department in an automobile. At first we analyzed the production process as indices of Overall Equipment Efficiency (OEE), balancing workloads and factory layout, where you can observe several opportunities for improvements such as: identification of bottlenecks restricting the production flow; reduction of production batches in process, takt time reduction; layout changes and increased productivity. From there, it was possible to implement actions to improve the performance of the production process, both in the implementation of tools such as continuous improvement. The results showed that the use of correct techniques Theory of Constraints integrated the concepts of Lean Manufacturing can generate substantial gains in competitiveness, including overcoming the goals of the organization, as was found in this study.

En la actualidad, la industria textil equivale al 7.2% del PBI de las empresas manufactureras y es el segundo grupo con mayor participación en el mercado, pues tiene un impacto significativo en la economía del país. Sin embargo, ha sufrido gran inestabilidad en sus ventas debido a la alta competitividad proveniente sobre todo del sudeste asiático, quienes han llevado consigo producciones de alto volumen con costos operativos por debajo del mercado, frente a ello, muchas compañías han optado por la tercerización de diversas etapas de la producción con la finalidad de disminuir sus costos. La baja productividad, la variabilidad de sus procesos, los sobrecostos operativos, los largos tiempos de producción, entre otros, son las principales causas de la brecha que existe en el sector y a las cuales se debe atacar. Por lo tanto, el propósito de esta investigación es aportar a la industria textil con metodologías y herramientas que le permitan ser competitiva en el sector, logrando disminuir los sobrecostos operativos. Se analizará un estudio de caso real aplicado a una empresa denominada TEXTIL S.AC. siguiendo la aplicación del trabajo combinado que permita integrar mano de obra, método de trabajo y máquinas y con ello las mudas como los productos con defectos que incurre en gastos para la compañía. Los principales resultados permitieron concluir que las herramientas Lean son efectivas para normalizar el proceso y con ello lograr reducir la variabilidad y aumentar la productividad de una empresa textil. / Currently, the textile industry is equivalent to 7.2% of the GDP of manufacturing companies and is the second group with the largest market share, as it has a significant impact on the country's economy. However, it has suffered great instability in its sales due to the high competitiveness coming especially from Southeast Asia, who have carried out high-volume productions with operating costs below the market, compared to this, many companies have opted for outsourcing of Various stages of production with the proposal of reducing their costs. Low productivity, the variability of its processes, operating cost overruns, long production times, among others, are the main causes of the gap that exists in the sector and which must be attacked. Therefore, the purpose of this research is to contribute to the textile industry with methodologies and tools that will be competitive in the sector, reducing operating costs. A real case study applied to an affected company TEXTIL S.AC. will be analyzed. following the application of the combined work that allows integrating labor, work method and machines and with it the changes as products with defects that incur costs for the company. The main results led to the conclusion that Lean tools are effective in normalizing the process and thereby reduce variability and increase the productivity of a textile company. / Trabajo de investigación

La existencia de retrasos en la entrega de pedidos en las pymes del sector textil-confección, la creciente demanda de los clientes por obtener un producto de calidad y percibir los pedidos a tiempo ha obligado a las organizaciones a implementar modelos de mejora en sus sistemas productivos. Por tal motivo, este artículo propone utilizar un modelo que se adapte a la reducción de tiempos de entrega en las líneas productivas de empresas de confección basado en la aplicación de manera combinada de buenas prácticas, herramientas y conceptos de manufactura esbelta. Esta combinación se enfatiza en la utilización del mapa de flujo de valor (VSM) como herramienta de diagnóstico, estandarización como oportunidad de mejora y un sistema modular que resalta conceptos esbeltos que son aplicables para minimizar el tiempo de inventarios en proceso. Logrando obtener como resultado la reducción de un 24% en el tiempo de espera total de las prendas. / The existence of delays in the delivered orders in SMEs in the clothing sector, the growing demand of customers to obtain a quality product and receive the orders on time has forced organizations to implement improvement models in their production systems. For these reasons, this article proposes to use a model that adapts to the reduction of delivery times in the production lines of garment companies based on the combined application of good practices, tools and concepts of lean manufacturing. This combination emphasizes the use of the value stream map (VSM) as a diagnostic tool, work standardization as an opportunity for improvement and a modular system that highlights lean concepts that are applicable to minimize the time of inventories in process. Achieving a 24% reduction in the total lead time of the garments. / Trabajo de investigación

Hoy en día, las organizaciones en la industria de prendas de punto de algodón han tenido que adaptarse a un cliente que no está dispuesto a pagar un costo adicional por actividades que no agregan valor al producto. En Perú, las empresas exportadoras de prendas de punto de algodón cierran todos los años, ya que no pueden competir con países como China y Hong Kong debido a sus altos costos de producción. Por lo tanto, el objetivo de este artículo es desarrollar un modelo de gestión de producción basado en técnicas de manufactura esbelta y estandarización de operaciones para reducir el desperdicio en el flujo de producción, mejorando así la calidad y reduciendo el tiempo y los costos de producción. Para esto, se implementaron el modelo de producción y la mejora continua (PDCA). Fue validado en una empresa exportadora de prendas de punto de algodón en Perú, donde fue posible obtener como mejora la eficiencia en un 10%, reducir los productos defectuosos en un 20% y generar ahorros de 5,000 soles por mes. / Nowadays, organizations in the cotton knitwear industry have had to adapt to a client who is not willing to pay an additional cost for activities that do not add value to the product. In Peru, exporting companies of cotton knitwear are closed every year, since they cannot compete with countries such as China and Hong Kong due to their high production costs. Therefore, the aim of this article is to develop a production management model based on Lean Manufacturing techniques and standardization of operations to reduce waste in the production flow, thus improving quality, and reducing production time and costs. For this, Production model and Continuous improvement (PDCA) were implemented. It was validated in an export company of cotton knitwear in Peru, where it was posible to obtain as an improvement the efficiency by 10%, reduce defective products by 20% and generate savings of 5,000 soles per month. / Trabajo de investigaciòn