The topic of my dissertation is "Organization and management of production in selected enterprise". The main goal of this dissertation is mapping of selected enterprise in one year period and obtain sufficient amount of information for future analysis and suggest possible improvements. The identification data, characteristic, products and services and production planning of selected enterprise are provided in introduction of practical part of this dissertation. Analysis of present state with mapping of present state for individually semi-finished products is introduced in the next part of dissertation. For analysis of present state was calculated VA index and for each semi-finished product was created diagram of material movement in next chapter. The goal of analyses and diagram is the finding of narrow spaces in the material flow. The target map of future state was created in the next part. This map is based on present map. The future map presents critical factors that need to be improved. Finally it defines a new VA index, which should be approach to the current state. The penultimate section includes recommendations methods and elements of lean production to the new production hall which the company wants to build. Among the recommended methods are mainly the 5S method, visualization, standardization, SMED and Bottleneck. The last chapter contains a number of measures. For example employee motivation, continuous improvement, personal responsibility, introduction of EDI and ergonomics which would lead to the improvement of the business this enterprise.

This dissertation is focused on a research of using methods of Lean Production in working environment of selected companies in the Czech Republic. In the introduction the author mentioned theoretic facts about Lean Production, which is originally from Japan. The rest of dissertation also included characteristics of selected companies and description of situations in companies before and after using Lean Production methods. At the end of each part we can find conclusion and suggestion of specific new steps for these companies. A company, called Linde Pohony s.r.o. Český Krumlov, have been using these methods: TPM, 5S and visual management. In a company Rohde & Schwarz, which is located in Vimperk, have been using the methods of Lean Production. : Kanban and also visual management. And a company ČSAT a.s. Praha have been testing methods of Lean Production: MUDA, 5S, Kaizen with a diagram of Ishikawa. In conclusion of the dissertation assumptions were evaluated. The overall summary of exercising Lean Production in companies - Linde Pohony s.r.o. Český Krumlov, ČSAT a.s. Praha a Rhode & Schwarz - Vimperk, were mentioned as well. Outcomes of the dissertation can be used for companies, which had been analyzing or for other companies with similar specializations. The dissertation provides the analysis of utilization selected Japanese principles of Lean Production in Czech companies.

In following a lean transformation specifically for discrete manufacturing, how and why will the organisational structure be affected? How will the employees deal with this profound change? Lean theory and literature propose that organisations should be restructured according to the value stream of the organisation; what does this imply and how can it be accomplished? The purpose of this study was to determine, from a new perspective, guidelines and theory that could indicate how and why organisational structures and behaviours might change with lean transformation. Two discrete manufacturing organisations in South Africa were purposively sampled for this purpose. A conceptual framework was used at the outset that indicated constructs for the independent lean variables and the dependent organisational structure and behaviour variables. Using a mixed methodology case study and quantitative multiple linear regression approach, hypotheses and propositions for the research were developed. Multiple linear regression was used to test the hypotheses, and case study methodology was applied to analyse and test the qualitative data. Findings confirmed the hypotheses and propositions that a flat structure consisting of business units that support manufacturing cells achieves effective lean transformations in discrete manufacturing organisations. The research revealed the components of an effective lean structure as open constructive leadership, an effective lean champions unit and business units that support linked manufacturing cells. These are led by cell leaders who cultivate supportive behaviours through cross-functional teamwork and through self-directed work teams who run manufacturing cells or flow support functions. / Business Management / D.B.L.

The thesis analyses manufacturing process of wooden handles as a component part of bench chisels. The introductory part summarizes basic theoretical knowledge regarding production process, production preparation, production management and cycle, as well as layout of the workplace. The main part focuses on analysis of wooden handle production with the use of in-dustrial engineering methodology. Analysis of material flow, workplace arrangement, methodics 5S, low-cost automation, pull system, Kanban and utilization of waste were carried out in order to find improvement possibilities in the wooden handles production. Solutions for better production efficiency and increase of production capacity are proposed from the findings of this thesis.

Made available in DSpace on 2016-06-02T19:51:49Z (GMT). No. of bitstreams: 1 3634.pdf: 1481408 bytes, checksum: d561cb2e4ab6a3abae07e5e1e88e2b20 (MD5) Previous issue date: 2011-02-25 / Financiadora de Estudos e Projetos / The use of lean manufacturing principles and techniques has been increasing considerably in companies over the past couple of decades. The employment of such techniques prompts profound transformations on both the project and work organization of the company that chooses to employ them. By this approach, companies that embrace the lean manufacturing model gain flexibility, acquire new principles, and adopt new techniques which enhance their manufacturing process management as well as their workforce management, supported upon the motivation of the worker as he performs his activities, upon team-work, and stimulated by qualification and engagement at work. The objective of this study is to deepen the knowledge of how workmen develop strategies and regulate work activities in productive situations that are planned and managed through principles and techniques based upon the lean manufacturing concept. In order to more clearly analyze the theme studied, a case study was conducted in the assembly line of a company that incorporated the lean manufacturing model to manage its manufacturing process. Work was analyzed through the analysis of activity, based on the precepts of the Ergonomic Analysis of Work. The case study certified that many aspects of the traditional assembly line remain evident in the lean assembly line; however, a new language is employed, due to the new culture and the more flexible model of lean manufacturing. Within the work situations that were analyzed in the case study, it was possible to establish some relevant aspects in the nature of regulations in which their relation to the lean techniques influence the strategies and operational modes of the workers during the process. Despite the diminishment of regulated space which takes place due to the application of lean manufacturing techniques, the operators continue to regulate work activities and fulfil production goals. / A utilização dos princípios e técnicas do modelo de produção enxuta tem crescido consideravelmente nas empresas nas últimas décadas. A ampliação da adoção das técnicas da produção enxuta nas empresas resulta em profundas transformações sobre o projeto e a organização do trabalho. Para essa abordagem, as empresas que adotam a produção enxuta passam a ser mais flexíveis, a ter novos princípios e a adotar novas técnicas na gestão da produção e da força de trabalho, apoiados na motivação do operário na execução de suas atividades, no trabalho em equipe, estimulados pelas qualificações e engajamento no trabalho. Diante disso, a ergonomia considera que as mudanças dos espaços de regulação fazem com que os trabalhadores adotem estratégias e modos operatórios a fim de regular seu estado interno e atingir os resultados esperados pela organização Esse estudo teve por objetivo aprofundar os conhecimentos sobre como os trabalhadores desenvolvem estratégias e regulam a atividade de trabalho em situações produtivas projetadas e geridas nos princípios e técnicas baseados na produção enxuta. Para melhor problematizar o tema estudado, foi realizado um estudo de caso em uma linha de montagem de uma empresa que adotou a produção enxuta como maneira de gerir a sua produção. O trabalho foi analisado utilizando como método a análise da atividade, apoiada nos pressupostos da Análise Ergonômica do Trabalho. No estudo de caso foi constatado que muitos aspectos da linha de montagem tradicional continuam evidentes na linha de montagem enxuta, porém utilizando-se de uma nova linguagem, devido à nova cultura, mais flexível do modelo de produção enxuta. Dentro das situações do trabalho analisado no estudo de caso foi possível constatar alguns aspectos relevantes na natureza das regulações, cuja relação com as técnicas enxutas influenciam nas estratégias e modos operatórios dos trabalhadores, durante o processo. Apesar da diminuição dos espaços de regulação com a utilização das técnicas da produção enxuta, os operadores, ainda assim, continuam a regular a atividade de trabalho e atingir os objetivos de produção.

Made available in DSpace on 2016-06-02T19:51:53Z (GMT). No. of bitstreams: 1 4187.pdf: 1933710 bytes, checksum: a9f95ff8a1d0a965328143123fd90b7f (MD5) Previous issue date: 2012-02-27 / Financiadora de Estudos e Projetos / ABSTRACT Lead time reduction results in significant gains. This reduction is achieved through improvements programs in six different shop floor parameters. Two approaches, namely, Lean Manufacturing and Theory of Constraints have different tools and techniques with different improvement allocations in a production line. The tools and techniques of the first suggest improvements spread along the line. The second one advocates that the focus of improvements should be just on the constraint resource. In this context, this study investigates what is the best allocation of improvement programs regarding lead time reduction, a large improvement on the constraint resource, or, alternatively, small improvements on all workstations. In the present study, a quantitative model that relates System Dynamics (Forrester, 1961) and Factory Physics (Hopp; Spearman, 2001) approaches, created by Godinho Filho and Uzsoy (2008a; 2008b; 2009) is used. The results indicate that when constraint resource utilization is high and the difference in the utilization between constrained resource and non-constrained resource is significant (over 5%), a large investment constraint resource option is best. As the utilization of the constrained resource and the difference between the utilization of constrained and non-constrained resources decreases, the improvement program at various points of the line begins to behave better. This decrease in the difference between the utilization of constrained and non-constrained resource can be understood as a trend toward a balanced line. Lastly, if in practice, there is a balanced line and the constrained resource prevails over the non-constrained resource, the best option is a great concentrated investment at the constrained resource. However, might be situations where a great investment at the constrained resource is impracticable and the results of this work suggest that an hybrid approach is interesting when the constrained resource have higher utilizations (99,8% and 99,5%), already, when the utilization of the constrained resource is 90,5% a good option is the allocation of the improvement programs at various points of the line. / A redução do lead time implica em ganhos significativos. Essa redução é obtida por meio de programas de melhorias em variáveis do chão de fábrica. Duas abordagens, a saber, Manufatura Enxuta e Teoria das Restrições, possuem técnicas e ferramentas que se propõem a alocar programas de melhoria em diferentes locais de uma linha produtiva. As técnicas e ferramentas da primeira sugerem melhorias distribuídas por todas as estações de trabalho, enquanto a segunda afirma que o foco das melhorias deve ser alocadas apenas no recurso restrição. Nesse contexto, este trabalho investiga qual a melhor alternativa de alocação de programas de melhoria com relação à redução do lead time, ou seja, implementar melhorias em variáveis do chão de fábrica somente no recurso restrição, ou, alternativamente, em todas as estações de trabalho. No presente estudo é utilizado um modelo quantitativo que relaciona as abordagens de System Dynamics (FORRESTER, 1961) e Factory Physics (HOPP; SPEARMAN, 2001) criado por Godinho Filho e Uzsoy (2008a; 2008b; 2009). Os resultados indicam que quando a utilização do recurso restrição de capacidade for alta e a diferença na utilização do mesmo e os recursos não restritivos for significativa (acima de 5%), um investimento grande e concentrado é a melhor opção. Conforme tanto a utilização do recurso restrição de capacidade quanto a diferença entre recurso restrição de capacidade e recursos não restritivos diminuem, o programa de melhoria em vários pontos da linha começa a se comportar melhor. A diminuição na diferença entre a utilização do recurso restrição e não restrição pode ser entendida como uma tendência ao balanceamento da linha, o que favorece a alocação de programas de melhoria em vários pontos da linha. Por fim, se na prática, houver a presença de uma linha não balanceada e o recurso restrição de capacidade estiver com alta utilização e se sobressair em relação aos recursos não restrição, a melhor alternativa é realizar um investimento grande e concentrado no recurso restritivo. Entretanto, pode haver situações em que efetuar uma grande melhoria concentrada no gargalo é proibitiva e os resultados sugerem que uma abordagem de melhoria híbrida é interessante para essa situação quando o recurso restrição de capacidade apresentar altas utilizações (99,8 e 95,5%), já na presença de um recurso restritivo com utilização de 90,5% a alocação de programas de melhoria direcionada a vários pontos da linha é indicada.

Submitted by Fabio Medeiros (medeirosfb@hotmail.com) on 2018-08-29T19:18:50Z No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Approved for entry into archive by Mayara Costa de Sousa (mayara.sousa@fgv.br) on 2018-09-05T18:08:23Z (GMT) No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Approved for entry into archive by Suzane Guimarães (suzane.guimaraes@fgv.br) on 2018-09-06T12:15:47Z (GMT) No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) / Made available in DSpace on 2018-09-06T12:15:47Z (GMT). No. of bitstreams: 1 DissertaçãoOficial_FabioMedeiros_Final_2018-07-13.pdf: 1886756 bytes, checksum: 97237a802cf505a292bc9315360ed503 (MD5) Previous issue date: 2018-07-04 / As grandes corporações têm intensificado a otimização de suas redes logísticas, entendendo a importância estratégica que a área de operações possui, não somente em relação a liberação de recursos através de redução de custos, mas também na geração de valor através dos serviços prestados a seus clientes. Este movimento trouxe consigo um amplo desenvolvimento tecnológico para as operações de distribuição e logística. No que diz respeito a automação, existe uma evolução significativa, principalmente nos processos internos dos centros de distribuição, tais como: sistemas inteligentes de guarda e retirada de produtos, operações de empilhadeiras sem tripulação humana, carregamento e descarregamento mecanizado de caminhões, sistemas automatizados de separação de pedidos e máquinas para montagem e fechamento de caixas, entre outros exemplos. No entanto, não há uma grande variedade de estudos de casos sobre operações, já automatizadas, que elevaram seus níveis de produtividade e qualidade significativamente, sem investimentos de capital, mas através de redesenho de processos e atuação das lideranças operacionais. Este trabalho, portanto, tem como objetivo capturar e demonstrar o que foi realizado para se obter ganhos significativos em produtividade e qualidade nas operações logísticas através desta união: ferramentas de melhoria contínua e atuação das lideranças, sem o uso de investimentos de capital. O problema de pesquisa está focado, então, em capturar e demonstrar as iniciativas implementadas durante a transformação pela qual o processo de distribuição da empresa passou em relação as suas atividades logísticas, bem como as ferramentas de melhoria contínua utilizadas. Para tanto, foi realizada uma pesquisa do tipo estudo de caso da operação logística da Avon Cosméticos no Brasil, entre os anos de 2015 a 2017, que passou por este processo de transformação. Como resultado, espera-se detalhar estes projetos e iniciativas implementados bem como as metodologias ou ferramentas aplicadas, as melhorias obtidas e a conexão entre teoria e prática. Como aporte deste trabalho, espera-se reforçar a teoria existente sobre melhoria contínua de processos, contribuindo assim com os mundos acadêmico e empresarial no que diz respeito a otimização de operações. / Large corporations have intensified the optimization of their logistics networks, understanding the strategic importance that the operations area has not only related to the resources release through cost reduction, but also in value generation through the services provided to its customers. This movement brought with it a broad technological development for distribution and logistics operations. As far as automation is concerned, there is a significant evolution, especially in the internal processes of distribution centers, such as: intelligent systems for guarding and withdrawing products, forklift operations without human crew, mechanized loading and unloading of trucks, automated separation of orders and machines for assembly and boxes closing, among other examples. However, there is not a wide range of case studies on operations, which are already automated, that have raised their levels of productivity and quality significantly, without capital investments, but through processes redesign and the performance of operational leadership. This work, therefore, aims to capture and demonstrate what has been done to achieve significant gains in productivity and quality in logistics operations through this union: tools for continuous improvement and leadership performance, without significant use of capital capex. The research problem is then focused on capturing and demonstrating implemented initiatives during the transformation by which this company's distribution process passed related to its logistic activities, as well as the continuous improvement tools used. To do so, a case-study of the logistics operations of Avon Cosmetics in Brazil, between the years of 2015 and 2017, was carried out. As a result, it is expected to detail these projects and initiatives implemented as well as the methodologies or tools applied, the improvements obtained and the connection between theory and practice. As a contribution of this work, it is hoped to reinforce the existing theory on continuous process improvement, thus contributing to the academic and business worlds regarding to operations optimization.

O objetivo geral deste trabalho é estudar em uma indústria automotiva a redução dos custos de refugos e retrabalhos causados por não qualidade de fabricação ou devido a anomalias nos transportes das peças compradas de fornecedores da Europa. Para a obtenção dos resultados, o método utilizado inicialmente foi a pesquisa bibliográfica fornecendo a base para o estudo de caso descritivo em uma indústria automotiva. Este trabalho teve como finalidade a pesquisa aplicada, pois foi motivada pela resolução de um problema concreto, que é a redução destes custos. Inspirado nas ferramentas da Manufatura Enxuta foi criado um grupo de trabalho para elaborar um procedimento de re-faturamento dos custos de não qualidade dos fornecedores da Europa e aplicado a metodologia Hoshin para a melhoria nos processos da seguradora em caso de sinistros nos transportes destes fornecedores. Para resolver estes problemas as ferramentas da qualidade foram amplamente utilizadas. Foi possível re-faturar os fornecedores Externos da Europa em cerca de R$ 635.000,00 e reduzir R$ 305.312,00 de custos com refugos dos Fornecedores Internos da Europa. A aplicação do procedimento estimulou os Fornecedores Internos e Externos e o custo mensal com refugos considerando o re-faturamento passou de R$ 86.973,00 para R$ 10.104,00. O custo por veículo foi de R$ 10,32 para R$ 3,74. O ganho total somado até 2009 foi de R$ 1.238.476,00. / The general purpose of this work is to study, in an automotive industry, the reduction of the costs of scrap and rework caused by no manufacturing quality or due to deficiencies in transport parts purchased from suppliers in Europe. To obtain the results the method was initially used to search bibliographic providing the basis for the descriptive case study in an automotive industry. This study was aimed at applied research, because it was motivated by solving a real problem, which is the reduction of these costs. Inspired by the tools of Lean Manufacturing it was created a working group to develop a procedure for invoicing again the not quality costs from European suppliers as well as the methodology was applied Hoshin to improve the processes of insurer in case of accidents in transport of these suppliers. To solve these problems the quality tools have been widely used. It was possible to invoice again from external suppliers in Europe about R$ 635.000,00 and lower R$ 305.312,00 in costs with scraps of domestic suppliers in Europe. Applying the procedure prompted the internal and external suppliers and the monthly cost with scrap considering the re-sales rose from R$ 86.973,00 to R$ 10.104,00. The cost per vehicle was R$ 10,32 to R$ 3,74. The gain added by 2009 was R$ 1.238.476,00.

La investigación está orientada al diseño e implementación de un Modelo Integrado de Gestión de la Producción para la fabricación de llaves de cerradura, este modelo integra la teoría de restricciones para resolver los cuellos de botella y utiliza algunas herramientas de Lean Manufacturing para eliminar los desperdicios que se generan en los procesos que generan los cuellos de botella. El objetivo de la aplicación del modelo es el mejorar la productividad de la línea de fabricación de llaves de cerradura, la reducción de costos mediante la mejora de la eficiencia de sus procesos que permitan a la empresa ser más competitiva en el mercado. The research is focused on the design and implementation of an integrated management of production for the manufacture of keys lock model, this model integrates the theory of constraints to solve bottlenecks and used some tools of lean manufacturing to eliminate waste that is generated in the processes that create bottlenecks. The purpose of applying the model is to improve the productivity of the manufacturing line lock keys, reducing costs by improving the efficiency of their processes that enable the company to be more competitive in the market.

Les systèmes assemble-to-order (ATO) peuvent être considérés comme une affectation de ressources multiples qui induit planification de production, satisfaction des contraintes et affectation des stocks. Les systèmes ATO représentent une stratégie de logistique populaire utilisée en gestion de fabrication. En raison de la complexité croissante des systèmes de fabrication d'aujourd'hui, le défi pour les systèmes ATO est de gérer efficacement les stocks de composants et de trouver les décisions optimales de production et d'affectation.Nous étudions un système ATO avec un produit unique qui est assemblé à partir de plusieurs composants. Le système doit répondre à une demande non seulement du produit assemblé, mais aussi des composants individuels. Nous considérons le cas avec seulement des lost sales puis le cas mixte lost sales et backorders avec des temps de production suivant des lois de type exponentiel et une demande sous forme de loi de Poisson. Nous formulons le problème comme un Processus de décision markovien (MDP), et nous considérons deux critères d'optimalité qui sont le coût actualisé et le coût moyen par période. Nous caractérisons la structure de la politique optimale et étudions l'impact des différents paramètres du système sur cette politique. Nous présentons également plusieurs heuristiques pour le cas lost sales et le cas mixte lost sales et backorders. Ces heuristiques fournissent des méthodes simples, mais efficaces pour contrôler la production et l’affectation des stocks du système ATO / Assemble-to-order (ATO) systems can be regarded as a multiple resource allocation that induces production planning, requirements fulfilling and inventory assignment. ATO is a popular strategy used in manufacturing management. Due to the increasing complexity of today’s manufacturing systems, the challenge for ATO systems is to efficiently manage component inventories and make optimal production and allocation decisions. We study an ATO system with a single product which is assembled from multiple components. The system faces demand not only from the assembled product but also from the individual components. We consider the pure lost sales case and the mixed lost sales and backorders case with exponential production times and Poisson demand. We formulate the problem as a Markov decision process (MDP), and consider it under two optimality criteria: discounted cost and average cost per period. We characterize the structure of the optimal policy and investigate the impact of different system parameters on the optimal policy. We also present several static heuristic policies for the pure lost sales and the mixed lost sales and backorders cases. These static heuristics provide simple, yet effective approaches for controlling production and inventory allocation of ATO system