This thesis discusses and demonstrates the benefits of simulating and optimising a manufacturing control system in order to improve flow of production material through a system with high variety low volume output requirements. The need for and factors affecting synchronous flow are also discussed along with the consequences of poor flow and various solutions for overcoming it. A study into and comparison of various planning and control methodologies designed to promote flow of material through a manufacturing system was carried out to identify a suitable system to model. The research objectives are; • Identify the best system to model that will promote flow, • Identify the potential failure mechanisms within that system that exist and have not been yet resolved, • Produce a model that can fully resolve or reduce the probability of the identified failure mechanisms having an effect. This research led to an investigation into the main elements of a Drum-Buffer-Rope (DBR) environment in order to generate a comprehensive description of the requirements for DBR implementation and operation and attempt to improve the limitations that have been identified via the research literature. These requirements have been grouped into three areas, i.e.: a. plant layout and kanban controls, b. planning and control, and c. DBR infrastructure. A DBR model was developed combined with Genetic Algorithms with the aim of maximising the throughput level for an individual product mix. The results of the experiments have identified new knowledge on how DBR processes facilitate and impede material flow synchronisation within high variety/low volume manufacturing environments. The research results were limited to the assumptions made and constraints of the model, this research has highlighted that as such a model becomes more complex it also becomes more volatile and more difficult to control, leading to the conclusions that more research is required by extending the complexity of the model by adding more product mix and system variability to compare results with the results of this research. After which it will be expected that the model will be useful to enable a quick system response to large variations in product demand within the mixed model manufacturing industry.

Thesis (MBA)--University of Stellenbosch, 2009. / ENGLISH ABSTRACT: The political changes in South Africa since 1994 and globalisation have brought about a dramatic increase in competition for South African companies. To ensure long-term survival and success, companies have to focus their strategies on continuous improvement and the ability to adapt to continuous change. Lean manufacturing principles were derived from the Toyota Production System (TPS) which was created by Taiichi Ohna, who is widely credited to be the father of Lean manufacturing principles. Lean principles originated in the automotive industry and transformed an industry that previously focused all its improvement efforts on the theory of mass production. Lean principles can be summarised as continuous improvement through focus on the elimination of waste from processes. Lean principles specify that organisations: • Change from using their view to using the view of the customer when evaluating value-creating activities; • Change production plans that focus on mass production to production plans that produce only what customers want now in flow production with small production batches; • Reduce lead times; • Improve quality; and • Achieve the above-mentioned by eliminating waste in all processes. Lean principles are based on the assumption that once waste is removed, the process improves and results in reduced lead time, improved quality, reduced costs and improved customer service. The aim of this research study was to test Lean principles by implementing applicable parts of it in the engine rebuilding section of MultiMech, a division of Golden Arrow Bus Services. The changes that formed part of the implementation included: • Reduced work in progress through improved production planning; • Improved performance of inbound processes through improved communication based on improved production planning; and • Improved productivity due to improved inbound processes and improved performance measuring. The results from the pilot implementation of Lean principles at the engine rebuilding section support the benefits documented in the theory. The major results were: • An increase in the number of engines built for the months June to September, from 54 in 2007 to 88 in 2008 which represents a 63 per cent improvement in productivity; • A decrease in the number of works orders from 58 to 21, which represents a decrease of 63 per cent in work in progress; and • A reduction in stores' lead time from 3.5 days to 1.4 days, which represents an improvement of 60 per cent. The results from the pilot implementation is only an indication of the total potential that will be realised when Lean principles are implanted throughout MultiMech. / AFRIKAANSE OPSOMMING: Die politieke veranderinge in Suid-Afrika sedert 1994 en globalisering het 'n dramatiese verhoging in mededinging vir Suid-Afrikaanse maatskappye tot gevolg gehad. Ten einde langtermyn oorlewing en sukses te verseker, moet maatskappye hul strategiee fokus op aanhoudende verbetering en die vermoe om by konstante verandering aan te pas. 'Spilvrye' vervaardigingsbeginsels ('Lean manufacturing principles') is afgelei van die Toyota produksiestelsel ('Toyota production system') (TPS), wat ontwikkel is deur Taiichi Ohno, wat algemeen beskou word as die vader van spilvrye vervaardigingsbeginsels. Hierdie beginsels het ontstaan in die motorvervaardigingsindustrie en 'n industrie transformeer wat voorheen al sy verbeteringspogings gefokus het op die teorie van massaproduksie. Spilvrye beginsels kan opgesom word as konstante verbetering deur te fokus op die eliminasie van verspilling uit prosesse. Spilvrye beginsels bepaal dat organisasies: • Nie meer vanuit hulle eie perspektief nie, maar vanuit die klient se perspektief waardeskeppende aktiwiteite beoordeel; • Produksieplanne verander wat fokus op massaproduksie tot produksieplanne wat slegs produseer wat kliente nou wil he in 'n vloeiproduksieproses met klein produksievolumes; • Wagperiodes verminder; • Kwaliteit verbeter; en • Bogenoemde bereik deur verspilling in alle prosesse te elimineer. Spilvrye beginsels is gebaseer op die aanname dat sodra verspilling verwyder is, die proses verbeter en verkorte wagperiodes volg, kwaliteit verbeter, kostes verminder en klientediens verbeter. Die doel van hierdie navorsingstudie was om Spilvrye beginsels te toets deur toepaslike gedeeltes daarvan te implementeer in die enjinbou afdeling van MultiMech, 'n divisie van Golden Arrow busdienste. Die veranderinge wat deel uitgemaak het van die implementering sluit in: • Verminderde werk-in-proses deur verbeterde produksiebeplanning; • Verbeterde prestasie van inkomende prosesse deur verbeterde kommunikasie gebaseer op verbeterde produksiebeplanning; en • Verbeterde produktiwiteit as gevolg van verbeterde inkomende prosesse en verbeterde prestasiemeting. Die resultate van die loodsimplemetering van Spilvrye beginsels by die enjinbou afdeling ondersteun die voordele wat in die teorie gedokumenteer is. Die vernaamste resultate sluit in: • 'n Toename in die aantal enjins gebou vir die maande Junie tot September, van 54 in 2007 tot 88 in 2008 wat 'n 63 persent verbetering in produktiwiteit verteenwoordig; • 'n Afname in die aantal werksopdragte vanaf 58 tot 21, wat 'n afname van 63 persent in werk-in-proses verteenwoordig; en • 'n Afname in store se wagperiode van 3.5 dae tot 1.4 dae, wat 'n verbetering van 60 persent verteenwoordig. Die resultate van die loodsimplementering van Spilvrye beginsels is 'n teken van die totale potensiaal wat gerealiseer sal word met die implementering in ander departemente van MultiMech.

Tech. (Logistics, Faculty of Management Sciences), Vaal University of Technology / The focus of this study was to examine the relationship between information sharing, information quality, strategic partnership and internal lean practices among Small and Medium-sized Enterprises in South Africa. It is essential to understand practitioners’ and entrepreneurs’ current knowledge towards the topic at hand in order to determine what interventions would be most beneficial in helping to curb the problem of the lack of knowledge in this area and to understand the underlying causes behind the problem, while creating awareness and giving new insight to those who are already aware of this topic. Data was collected from a sample of 350 Small to Medium Enterprises and the measurement items in the measuring instrument were measured using a 5-point likert scale. Thereafter the collected data was coded and analysed by means of structural equation modelling using the AMOS 21 software package. The results indicate that supplier information sharing and information quality have a strong influence on strategic partnership and in turn strategic partnership has a strong influence on internal lean practices among Small to Medium Enterprises. This indicates that the level and quality of information shared between Small to Medium Enterprises and their suppliers has a positive effect on the strength of their partnerships as well as on the internal practices of each Small to Medium Enterprise. Based on these results, conclusions were drawn and recommendations were put forward on how internal lean practices in Small to Medium Enterprises can be improved by means of information sharing, information quality and strategic partnerships.

Orientador: Messias Borges Silva / Coorientador: Robisom Damasceno Calado / Banca: Otávio José de Oliveira / Banca: Nelson Tavares Matias / Banca: Fabrício Maciel Gomes / Banca: Rosinei Batista Ribeiro / Resumo: Esta pesquisa teve o objetivo de diagnosticar o nível de maturidade de diversas unidades produtivas de uma empresa do ramo químico e se elas poderiam ser consideradas Classe Mundial, identificando os pontos fortes e fracos da gestão de cada uma das fábricas analisadas, visando buscar oportunidades de melhoria em seu Sistema de Gestão. O método científico utilizado, as limitações da pesquisa e implicações, os resultados de investigação e pesquisa são exploratórios. O estudo foi feito por meio de uma pesquisa tipo Survey por análise combinada inicialmente qualitativa e em seguida quantitativa, referente ao grau de maturidade das empresas analisadas, utilizando-se do método de Análise de Correlação Grey. Referente ao método de pesquisa, foi utilizado o questionário combinado do LAI Enterprise Self-assessment Tool (Lesat) do Massaussuchets Institute of Technology (MIT) e Baldrige Performance Excellence Program do National Institute of of Standards and Techonology (NIST) do United States Department of Commerce, aplicados ao Método de Diagnóstico de Empresas (MDE). Pesquisas futuras podem ser realizadas em estudos de correlação entre um número maior de empresas de manufatura de outros segmentos. Este estudo amplo e com diversidade de organizações proporcionará um melhor entendimento do nível maturidade das organizações. A contribuição do estudo está na capacidade de diagnosticar o nível de maturidade da organização pesquisada. Avaliar se a aplicação das ferramentas do MDE, Lesat, B... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: This research had the purpose to diagnose the level of maturity of the several production plants in a chemical industry and evaluate if they could be consider World Class, in order to identify the strengths and weaknesses of the management of each of the analyzed factories, to identify opportunities for improvement in its Management System. The scientific method used, research limitations and implications, the results of investigation and research are exploratory. This study done through a survey type Survey combined qualitative analysis initially and then quantitative, concerning the degree of maturity of the factories analyzed, using Grey Correlation analysis method. Concerning the study method was the combined questionnaire LAI Enterprise Self-assessment Tool (Lesat) of Massachusetts Institute of Technology (MIT) and Baldrige Performance Excellence Program of the National Institute of Standards and Technology (NIST) of the United States Department of Commerce, using the Business Diagnostic Method (BDM). Future research can be carry out and correlation studies among a larger number of other branches manufacturing companies can be perform. A larger study with a diversity of organizations will provide a better understanding of the maturity level of the organizations. The contribution of this study is in the ability to diagnose the organization's maturity level. Evaluate if the application of BDM, Lesat & Baldrige and Grey System tools between the different factories inside a ... (Complete abstract click electronic access below) / Doutor

As operações industriais são objeto de muitas estratégias de gestão que visam melhorar o desempenho da empresa. Dentre estas estratégias podem ser encontradas a Produção Enxuta (Lean) e a Produção mais Limpa (P+L), implementadas de forma independente segundo objetivos distintos. Contudo, na prática, é frequente observar que as estratégias interagem dentro do contexto das indústrias, potencializando o ganho de desempenho operacional/ambiental ou prejudicando uma a outra quanto a seus objetivos. A academia vem recentemente evidenciando o possível relacionamento entre Lean e P+L dando principal atenção às interações positivas entre as estratégias, havendo poucos trabalhos que observam as interações negativas ou estudam os mecanismos pelos quais é possível descrever seu relacionamento. Como resposta a esta lacuna, esta pesquisa tem por objetivo principal propor diretrizes para a integração entre o Lean e P+L nas empresas. Esta proposta de diretrizes se baseia no levantamento do estado da arte da integração entre as estratégias, que fornece as informações sobre o seu relacionamento, que são, por sua vez, verificadas empiricamente. Para executar essa estratégia de pesquisa foi feita a aplicação de dois métodos científicos: a Revisão Bibliográfica Sistemática (RBS) e o estudo de caso. A RBS, desenvolvida para analisar o conhecimento disponível sobre a integração entre Lean e P+L, investigou 5 bases de dados científicas através das quais foram avaliados 380 estudos, que após a aplicação de filtros e adição de estudos citados por estudos selecionados foi possível chegar a 38 relevantes para a avaliação da integração entre Lean e P+L. A partir desses estudos, que reúnem desde artigos em periódicos e conferências até relatórios de agências governamentais, foi possível obter informações iniciais sobre o relacionamento entre o Lean e P+L, por exemplo os principais temas de convergência e divergência e o fenômeno compartilhado entre as teorias, definidos segundo a literatura. Para verificação empírica dessas informações, foram feitos estudos de caso em duas empresas brasileiras e duas empresas inglesas para observar a integração em contextos diferentes e setores diferentes. Os estudos mostraram que, de maneira geral, os departamentos ambientais, onde a P+L é praticada, e de Lean se encontram distantes. Dessa forma, nos casos não havia iniciativa de integração entre o Lean e a P+L, mas sim interações espontâneas que levavam a benefícios os prejuízos de uma ou outra estratégia. O conhecimento, primeiramente obtido na literatura e depois submetido a uma avaliação empírica, foi reunido em diretrizes de integração dentro dos temas de integração entre o Lean e a P+L: Objetivos, Custos, Desperdícios, Ciclo de Vida, Risco Ambiental, Impactos Ambientais, Práticas, Consumidor e Sociedade, Cultura, Recursos Humanos, Requisitos Legais e Cadeia de suprimentos. Estes resultados contribuem para que, ao invés de uma abordagem segregada entre as estratégias, a sustentabilidade possa ser inserida diretamente dentro dos sistemas produtivos. Desta forma, a integração entre o Lean e a P+L passa a ser tanto uma resposta à demanda do consumidor por melhor desempenho ambiental quanto uma alternativa para que as empresas aumentem a eficiência de seus processos. / Industrial operations are the subject of many management strategies aimed at improving the company\'s performance. Among these strategies are Lean Manufacturing (Lean) and Cleaner Production (CP), implemented independently according to different goals. However, in practice, it is often observed that the strategies interact within the industries´ context, increasing the operational/environmental performance improvements or harming each others´ goals. The academy has recently started emphasizing the possible relationship between Lean and CP giving primary attention to the positive interactions between strategies, having few studies observed negative interactions or studied the mechanisms through which it is possible to describe their relationship. In response to this gap this research´s main objective is to propose guidelines for the integration between Lean and CP in companies. This guidelines proposition is based on a study of the state of the art of the integration between the two strategies which provided information about their relationship, that was in turn verified empirically. To run this search strategy two scientific methods were applied, the Systematic Literature Review (SLR) and the case study. The RBS was performed to analyze the available knowledge about the integration between Lean and CP investigated 5 scientific databases in which 380 studies were evaluated. After applying filters and adding studies cited by the selected studies, 38 studies were reached, which were the most relevant to the evaluation of the integration between Lean and CP. These studies ranged from journal and conference articles to government agencies reports, and from them it was possible to obtain the initial information about the relationship between strategies such as their main themes and the shared phenomenon defined according to the literature. For empirical verification of this information, case studies were performed in two Brazilian companies and two English companies to observe the integration in different contexts and different sectors. The studies have shown that in general the environmental departments, where CP is practiced, and Lean are distant. Thus no integration initiative between Lean and CP was observed, but spontaneous interactions that led to randomly to convergences and divergences. The knowledge obtained first literature and then subjected to an empirical evaluation was gathered in integration guidelines displayed according to the integration themes between Lean and CP: Objectives, Cost, Waste, Life Cycle, Environmental Risk, Environmental Impacts, Practices, Consumer and Society, Culture, Human Resources, Legal Requirements and Supply Chain. These results contribute to, rather than maintaining a segregated approach between strategies, inserting sustainability directly into the production systems. Consequently, the integration between Lean and CP becomes both a response to consumer demand for a better environmental performance and an alternative for companies that want increase processes efficiency.

O principal propósito deste trabalho é avaliar as principais variáveis que devem ser consideradas no dimensionamento do buffer de componentes de uma empresa que trabalha sob a ótica da Manufatura Enxuta, que devem ser fornecidos a uma célula de manufatura com mix variado de conjuntos similares a serem produzidos. Como mecanismo de validação da investigação, devido ao dinamismo inerente a operação de sistemas de produção com layout célular, foi utilizada a ferramenta Mapeamento de Fluxo de Valor com o apoio de uma estrutura de um software comercial de simulação computacional aplicando o otimizador do aplicativo desenvolvido a partir de um algoritmo genético a fim de contrapor o uso do abastecedor das células com o controle efetivo do nível de inventário do buffer. Como resultado são apresentados diferentes cenários definidos como experimentos tendo como principal fator a variação do tempo de ciclo de abastecimento executado e o fluxo de material como parâmetro inerente a demanda por cada um dos componentes consumidos na operação da célula de manufatura. Através das análises dos resultados foi concluído que os elevados níveis de estoque se tornam ou não necessários dependendo preliminarmente da capacidade de carregamento por ciclo de abastecimento do transportador e o tempo de ciclo necessário para a realização da atividade de ressuprimento. A relevância do tema de pesquisa estudado encontra-se na contribuição pertinente às informações adquiridas in loco na realidade de uma empresa que trabalha sob a ótica da Manufatura Enxuta, no crescente aumento da complexidade dos sistemas produtivos e, consequentemente, da dificuldade de análises mais precisas do impacto que as variáveis de fluxo, como por exemplo, tempo de abastecimento e movimentação, tempo de setup e os respectivos roteiros de fabricação podem causar no desempenho dos processos no chão de fábrica. / The main purpose of this work is to evaluate the main variables that must be considered in the component buffer dimensioning of a company that works with Lean Manufacturing, which to a manufacturing cell should be supplied with a varied mix of similar sets to be produced . As a research validation mechanism, due to the dynamism inherent in the operation of production systems with cell layout, the Value Stream Mapping tool was used with the support of a commercial software simulation structure applying the developed application optimizer from a genetic algorithm in order to counteract the use of the cell supplier with the effective control of the inventory level of the buffer. As a result, different scenarios defined as experiments are presented, the main factor being the variation of the supply cycle time executed and the material flow as a parameter inherent to the demand for each of the components consumed in the manufacturing cell operation. Through the analysis of the results it was concluded that high levels of stock become or not necessary depending on the loading capacity per transport cycle of the conveyor and the cycle time required to perform the resupply activity. The relevance of the studied research theme lies in the relevant contribution to the information acquired locally in the reality of a company that works from the perspective of the Lean Manufacturing, in the increasing complexity of the productive systems and, consequently, of the difficulty of more precise analyzes of the impact that the flow variables, such as supply and handling time, setup time and the respective manufacturing routes, can cause in the process performance on the shop floor.

A literatura revela que existe a oportunidade de se estudar formas de gerenciamento da melhoria de desempenho para desenvolvimento de produtos, sendo uma destas oportunidades a implementação dos princípios enxutos nesta atividade. O objetivo geral desta tese foi propor uma metodologia que possibilite, de forma estruturada, a utilização dos princípios e práticas enxutas no método de desenvolvimento de produto. A metodologia apoiou-se no resultado dos seguintes objetivos específicos: análise das práticas industriais, verificação de seu alinhamento com os princípios e práticas enxutas e identificação oportunidades de melhoria; identificação dos principais modelos existentes para criação de valor em ambientes outros que não o da manufatura; investigação mecanismos de integração para a equipe de desenvolvimento de produtos com base na mentalidade enxuta; identificação de uma plataforma de gestão que auxilie na implementação dos princípios enxutos no processo de desenvolvimento de produtos. O método de estudo de caso foi utilizado em três empresas – A, B e C – para coletar informações a respeito do processo de desenvolvimento de produtos. Seus resultados permitiram verificar o alinhamento de cada uma das empresas com as práticas enxutas, e a conseqüente verificação de sua aplicabilidade. As inferências obtidas foram classificas em função dos seguintes aspectos: entendimento da empresa com relação aos princípios enxutos aplicados ao processo de desenvolvimento de produtos, identificação de valor, fluxo de valor, sistema puxado e perfeição. Pautada nestas inferências, foi elaborada uma proposta de metodologia para implementação de princípios enxutos no processo de desenvolvimento de produtos visando a conseqüente melhoria do processo. A metodologia proposta foi aplicada a uma quarta empresa – D. Os resultados foram que a metodologia, de forma geral, mostrou-se consistente com seus objetivos, dentre os quais o principal foi a melhoria do processo de desenvolvimento de produtos. / In the literature, an opportunity appears to study performance improvement management forms for product development. One of these opportunities is the implementation of lean principles in this activity. The general objective of the thesis was to propose a methodology, which enables the utilization of the lean principles and practices in the product development method in a structured form. The methodology was based upon the result of the following specific objectives: the analysis of industrial practices, the verification of their alignment with the lean principles and practices and the identification of improvement opportunities; the identification of the main existing models for weighting creation in environments other than manufacturing; an integration mechanism investigation for the product development team, based on the lean mentality; and the identification of a management platform, which helps in the implementation of the lean principles in the product development process. The case study method was utilized in three companies – A, B and C – in order to collect information with respect to the product development process. The results enabled the verification of the alignment of each one of the companies as to their lean practices and the consequent verification of their applicability. The obtained inferences were classified according to the following aspects: the understanding of the company with regard to the lean principles applied to the product development process, the weighting identification, importance flow, in-depth system used and perfection. A methodology proposal was drawn from these inferences, for the implementation of the lean principles in the product development, having in mind the consequent process improvement. The proposed methodology was applied to a fourth company – D. The results showed that in a general manner, the methodology was consistent with its objectives, of which the main one was the improvement of product development.

El presente proyecto de investigación se encuentra estructurado en cinco capítulos principales los cuales son: Marco teórico, Análisis y Diagnóstico de la situación actual, Diseño y Desarrollo, validación y evaluación de impactos y por último conclusiones. El objetivo del presente trabajo es reducir el lead time excesivo (23 días) en las pymes exportadoras del sector de prendas de vestir en el Perú, el cual fue identificado en las visitas a la muestra significativa de 46 empresas y luego plasmada la información recopilada en un value stream map. A partir de un análisis de causas raíces utilizando el método de diagrama causal, se identificó que las principales causas son los desperdicios de reproceso (40,46%), tiempo improductivo (39,9%) y defectos (28.5%) siendo las causas raíces área de trabajo desordenado, inadecuado método de trabajo, actividades de seguimiento no definidas, mal uso de mecanismos de control de versiones y uso de idiomas extranjeros. Para reducir el lead time excesivo a partir de las causas raíces identificadas, se propone implementar las herramientas lean (5S y estandarización). Para ello, se propone la implementación de un manual de 5s, el uso de fichas técnicas e instructivos y un diccionario textil inglés – español. En conclusión, con la implementación de las propuestas lean 5s y estandarización se logra reducir el lead time excesivo de 23 días a 18 días, encontrándonos así en el promedio estándar del mercado. The present research project is structured into five main chapters which are: Theoretical framework, Analysis and Diagnosis of the current situation, Design and Development, validation and evaluation of impacts and finally conclusions. The objective of this paper is to reduce the excessive lead time (23 days) in the exporting SMEs of the garment sector in Peru, which was identified in the visits to the significant sample of 46 companies and then captured in the information collected in a value stream map. From an analysis of root causes using the causal diagram method, it was identified that the main causes are reprocess waste (40.46%), unproductive time (39.9%) and defects (28.5%) being the causes roots disordered work area, inadequate work method, undefined follow-up activities, misuse of version control mechanisms and use of foreign languages. To reduce the excessive lead time from the root causes identified, it is proposed to implement the lean tools (5S and standardization) especially the implementation of a 5s manual, the use of technical and instructive cards and an English - Spanish textile dictionary. In conclusion, with the proposals of implementation of the lean tools: 5s and standardization, it is possible to reduce the excessive lead time from 23 days to 18 days, thus finding us in the standard average of the market. / Tesis

Os desperdícios e a necessidade de oferecer um atendimento de qualidade constituem um verdadeiro desafio para as empresas de saúde. Para tanto, a adoção da filosofia enxuta - particularmente do lean healthcare - pode contribuir para a redução dos desperdícios e melhoria da qualidade. Neste contexto, este trabalho teve como objetivo analisar os motivos e como ocorreu a implantação do lean thinking nos processos de atendimento em uma empresa de medicina diagnóstica, bem como identificar os resultados alcançados. MÉTODOS: Trata-se de uma pesquisa exploratória de abordagem qualitativa, em que foi realizado um estudo de caso incorporado. Para a construção das questões orientadoras das entrevistas realizou-se uma pesquisa bibliográfica que gerou seis temas: operações, cultura organizacional, apoio da alta administração, redução de custos e desperdícios, foco no cliente e comunicação e capacitação. A coleta de dados foi realizada com dez participantes, divididos em três grupos e por meio de observações diretas. RESULTADOS: O modelo lean thinking foi aplicado na empresa pela iniciativa de líderes que conheciam o modelo. No entanto, ocorreu de forma incompleta - os colaboradores operacionais não foram envolvidos na capacitação inicial; os princípios básicos e ferramentas que fundamentam o modelo lean não foram incorporados como modelo de trabalho da empresa; não houve a integração de toda a organização, da alta administração à operação; os clientes não participaram do mapeamento do fluxo dos processos do atendimento e não avaliaram o que agrega valor. Com isso, os resultados alcançados em relação à redução de desperdícios com geração de valor ao cliente e melhoria da qualidade com a implantação do lean foram pontuais, com pouca adesão das lideranças e equipe de colaboradores. CONCLUSÕES: A análise dos resultados sugere que a implantação parcial da metodologia do lean thinking e suas práticas seguindo a literatura, considerando o contexto da organização, pode ter contribuído para a obtenção de um desempenho aquém do esperado, em termos de qualidade e redução de desperdícios. / The waste and the need to offer a quality service are a real challenge for healthcare companies. To this end, the adoption of lean philosophy - particularly the lean healthcare - can contribute to reduce waste and improve quality. In this context, this study aimed to analyze the reasons and how the implementation of lean thinking occurred in the processes of care in a medical diagnostic company, as well as identify the results achieved. METHODS: This was an exploratory qualitative study, in which an embedded case study was conducted. For the construction of the guiding questions of the interviews we carried out a literature search that yielded six themes: operations, organizational culture, top management support, cost reduction and waste, customer focus and communication skills. The data collection was performed with ten participants, divided into three groups and through direct observations. RESULTS: The lean thinking model was applied in areas of the company by the initiative of leaders who knew the model. However, there was incomplete - operational employees were not involved in the initial training; the basic principles and tools that support the lean model were not incorporated as a working model of the company; there was not integration of the entire organization, from top management to the operation; customers did not take part on the flow mapping of the processes of care and did not evaluate what adds value in customer perception. Thus, the results achieved regarding wastes decrease with customer value development and quality improvements through lean deployment were punctual and presented poor uptake from leadership team and employees. CONCLUSIONS: The assay of achieved results suggests that the incomplete lean thinking methodology deployment and its best practices according to the literature, also taking into consideration the context among enterprise under study, may have contributed for achievements lower than expected, in relation to quality and wastes decrease.

El principal desafío de las Pymes del sector textil de confecciones es el nivel de competitividad que se vive en la actualidad. Las empresas textiles, deben tener la capacidad de atender los diferentes pedidos en el tiempo establecido por el cliente final. En este contexto, es fundamental desarrollar métodos o herramientas que mejoren los procesos deficientes del sector. El objetivo principal del proyecto es rediseñar el proceso de compra con herramientas de lean manufacturing: Estandarización y Just in Time, alineados a eliminar los procesos innecesarios, elevar los niveles de productividad, reducir inventario, costos y tiempo de entrega e incrementar la satisfacción del cliente mejorando su competitividad en el mercado globalizado a través de los términos de agilidad, velocidad de respuesta y flexibilidad. Para el desarrollo del proyecto, se realiza una investigación previa sobre la metodología lean manufacturing, donde se estudian las aplicaciones de cada una de las herramientas y casos de éxito de PYMES a nivel mundial. Luego, se rediseña el proceso de compras del sector texil exportador orientado a las necesidades de las PYMES peruanas, acompañado de un plan de implementación de los módulos propuestos basadas en herramientas de lean manufacturing. Finalmente, el modelo propuesto es validado por juicio de expertos, dos usuarios de las empresas del sector textil y cuatro expertos en la aplicación de las herramientas Lean, a través de ocho criterios establecidos inicialmente se pudo determinar la viabilidad de la propuesta. The main challenge of the SMEs of the garment textile sector is the level of competitiveness that is experienced today. The textile companies must have the capacity to attend the different orders in the time established by the final client. In this context, it is essential to develop methods or tools that improve the deficient processes of the sector. The main objective of the project is to redesign the purchasing process with lean manufacturing tools: Standardization and Just in Time, aligned to eliminate unnecessary processes, raise productivity levels, reduce inventory, costs and delivery time and increase customer satisfaction improving its competitiveness in the globalized market through the terms of agility, response speed and flexibility. For the development of the project, a preliminary research is made on the lean manufacturing methodology, where the applications of each of the tools and success cases of SMEs are studied worldwide. Then, the purchasing process of the export textile sector oriented to the needs of Peruvian SMEs is redesigned, accompanied by an implementation plan of the proposed modules based on lean manufacturing tools. Finally, the proposed model is validated by expert judgment, two users of textile companies and four experts in the application of Lean tools, through eight criteria initially established it was possible to determine the viability of the proposal. / Tesis