Syfte: Branschen tampas fortfarande med kvalitetsbrister och har därför börjat uppmärksamma de fördelar som följer med industriellt byggande och standardiserade arbetsprocesser. Med industriella arbetsprocesser kan företagen ge frihet till arbetare att få ansvara för de arbetsprocesser som de medverkar i, och således bidra till att de förbättrar lösningar och standardiseringar. Ett koncept som lämpar sig väldigt väl för detta är The Toyota Production system (TPS), också kallat Lean production. År 2016 utfördes en samling fallstudier bland Lean-arbetande byggföretag där de visade att kvalitet och strävan efter standardiserade arbetsprocesser var högt prioriterat. Lean production och dess processer i företag omfattar informations – och kunskapsöverföringar och kan vara svårt att tillämpa. Därför motiveras vidare forskning på tillämpbarheten av principerna och dess verktyg i byggföretag. Studiens mål är att analysera hur företag inom prefabindustrin som arbetar med Lean kan utveckla sitt förbättringsarbete i produktionsprocessen. Metod: Rapporten är en kvalitativ fallstudie utförd på Ulricehamns Betong AB. Studiens datainsamlingsmetoder har varit litteraturstudier, deltagande observationer, semistrukturerade intervjuer och dokumentanalyser. Resultat: Utifrån studiens analys kunde vissa problem i förbättringsarbetet identifieras, samt leda till en analys över hur det förbättras och göras mer kunskapsdelande. Det framkom att inställningen till förbättringsarbete varierade stort bland medarbetarna. En gemensam syn på förbättringsarbetets betydelse krävs för fortsatt utveckling, något som kan uppmuntras från organisationens håll tydligare. Genom rollen som handledare kan företag säkra att det arbetas efter standardiserade arbetssätt. Konsekvenser: Avgörande för ett kunskapsdelande och utvecklande förbättringsarbete är att alla medarbetare är motiverade till att bidra till en förbättring. För att motivera medarbetarna bör statusen på individuell kunskap följt av inställning till kunskapsdelande att höjas. Medarbetare ska ha tillgång till kontinuerliga förbättringsmöten eller andra forum där de kan utbyta erfarenheter och idéer. Begränsningar: Fallstudien har genomförts på ett företag som använder sig av Lean-konceptet. Studien begränsas till att endast behandla förbättringsarbete i produktionen av prefabricerade betongelement.  Studien redogör alltså inte för hur andra prefab-företags förbättringsprocesser ser ut i produktionen. / Purpose: The industry is still struggling with reoccurring deficits regarding quality and has therefore began to pay attention what benefits that comes with an industrial building process. With industrial building processes the companies using it can let the workers be in charge of their work processes that they find themselves in and thus help to improve and standardise them. A concept that fits these conditions very well is The Toyota production system (TPS), also known as Lean production. In the year 2016 several studies were made that showed that among Lean working construction companies it was the reach for higher quality and standardised working processes that was prioritized. Lean production and its processes contains a lot of information- and knowledge transfers and may be hard to practice in a company. Therefore further studies on how to implement these principles and tools properly are recommended. The aim with this study is to analyse how companies in the precast industry who works with Lean can evolve their continuous improvement process in the production process.   Method: This report is a qualitative case study accomplished at Ulricehamns Betong AB. The chosen methods on how to collect data are literature studies, participating observations, semi-structured interviews and document analysis. Findings: From the analysis of this study some problems in the improvement process could be identified, but also how they could be improved and how they could be more knowledge sharing. It was shown that the will to participate in the improvement process did varied a lot among the co-workers. A common attitude for the importance of the improvement process is needed for the continuous development, something that can be more encouraged by the organisation. Through the implementation of a mentor the company can ensure that the production process is more standardised. Implications: The number one thing that is most important for an evolving and knowledge sharing improvement process is that the co-workers stay motivated to participate. To motivate them, the status of individual knowledge should be raised and heard. Furthermore they should have access to continuous improvement meetings or other forums where they can exchange experiences and ideas. Limitations: The case study has been accomplished at a company that are using the Lean concept. The study limits to only study the improvement process in the production process of precast concrete elements. Furthermore the study is focused on how one specific company uses their improvement process and not how other companies uses theirs.

Det här examensarbetet har utförts på Scania CV AB:s motorbearbetningsavdelning i Södertälje. I dagsläget pågår en omställning av tillverkningsprocessen på avdelningen där två nya tillverkningslinor, en för cylinderblock och en för cylinderhuvud, är under uppbyggnad. Linorna kommer styras med hjälp av ett Manufacturing Execution System. Ett Manufacturing Execution System har i uppgift att samla in data och information från tillverkningsprocessen, som sedan kan presenteras i ett gränssnitt. Vilken information som kommer finnas tillgänglig att presentera i systemet styrs utifrån en intern kravspecifikation som ska spegla International Society of Automation:s standard, även känd som ISA-95. Den kravspecifikation som finns för systemet är framtagen av IT-avdelningen i samråd med avdelningschefer. För närvarande är det osäkert om kravspecifikationen som finns på systemet stämmer överens med vad medarbetarna behöver för att kunna arbeta på ett effektivt sätt. Det här arbetet kartlägger behovet hos medarbetarna och jämför det med den befintliga kravspecifikationen. Genom intervjuer och enkäter har den befintliga kravspecifikationen för systemet jämförts med vad medarbetarna anser vara önskvärda funktioner i systemet. Resultatet av den första omgången intervjuer och enkätutskick var att kravspecifikationen och behovet hos medarbetarna stämmer väl överens. Det mynnade ut i att ytterligare en enkät skickades ut där medarbetarna istället skulle rangordna den information som kommer finnas tillgänglig i systemet utefter en prioriteringsskala i tre nivåer. Resultatet från den enkäten gav en bild av vilken information medarbetarna tycker är viktigast för att kunna arbeta på ett effektivt sätt. / This bachelor thesis has been done at Scania CV AB’s department for engine manufacturing in Södertälje. The manufacturing process at the department is currently under development, where two new lines are being added, one for cylinder head and one for cylinder blocks. These two new manufacturing lines are going to be controlled with the help of a Manufacturing Execution System. The Manufacturing Execution Systems task is to collect data and information from the manufacturing process, which later can be presented in an interface. There is a specification at Scania that presents what information will be available in the system. That specification is in line with what the International Society of Automation has specified in ISA-95. The specification for the system was set by the IT-department in consultation with department managers. There is currently an uncertainty if the specification meets the requirement that the workers has, to be able to work efficiently with the system. This thesis will identify the requirement that the workers has on the system, and compare it with the current specification. What the workers deems is necessary information has been identified and mapped through interviews and a survey. The result of these interviews and the survey made it clear that the specification was well in line with the requirement from the workers. This information led to the decision to send out another survey that asked the workers to prioritize how important the information in the system is, in three different priority levels. This resulted in an overview of what the workers consider is the most important information in the system.

The thesis developed in the field of study Electrical Manufacturing and Management is aimed at optimizing and streamlining of production plastics vacuum forming plastics technology rolled in a particular company. The theoretical part focused on the description of the principles of industrial engineering and survey methods that are fundamentals of lean manufacturing or the Toyota production system. The larger part is devoted to methods of 5S and SMED. The practical part of the optimization steps are designed to ensure increased production, balanced production and increase quality, which are based primarily on methods of 5S and SMED. To complement the work given the changes in production processes resulting from other methods of industrial engineering. Several proposals have been practically applied in the production are assessed and their benefits.

In today's competitive manufacturing environment, companies are constantly looking for ways to improve. Because of this, many companies are striving to become "lean" by implementing lean manufacturing, which is a difficult process. To aid in the implementation of lean manufacturing, simulation was used to reduce the trial-and-error period of lean manufacturing and find to optimum approach to implement the lean manufacturing principle. In this research, a case study of implementing level loading of the production schedule for BullFrog International, L.C. will be examined. To make it possible to implement level loading, the thermo-former machine at the beginning of the operations was improved to allow quick changeovers. The changeover time was reduced by 60% and with a few additional changes changeovers could be completely external. In order to be able to conduct simulation experiments to find the optimum production schedule, cycle times were gathered for each operation and a simulation model was developed of BullFrog International, L.C. current manufacturing operations. Historical data was gathered of previous month's sales orders and orders were divided into three different groups. Group 1 the spa orders are roughly 50% single-pump and 50% double-pump, group 2 the spa orders are roughly 60% or more single-pump spas and group 3 the spa orders are roughly 60% or more double-pump spas. Using historical data, level loading production schedules were developed using lean manufacturing principles by reducing lot sizes to the smallest possible and still preserving the correct ratios. All of these suggested production schedules were tested with the simulation model and through various experiments, the optimum production schedule were determined. The optimum production schedules were implemented and the results were recorded. The results were an average throughput increase of 49.1% in group 1, an average throughput increase of 58.7% in group 2 and an average throughput increase of 58.7% in group 3. These results support the hypothesis that level loading will increase throughput in a complex manufacturing system where there is a high mix and low volume production schedule. The results also support the hypothesis that the trial-and-error period was reduced by the use of simulation.

The global market is very competitive due to fast changes in complex business environments and to survive or expand the business, organizations must embrace organizational change. However, adapting to change is not always easy, where organizations may experience obstacles and resistance along the way. Organizations may also experience that it is very hard to implement lean successfully, due to lack of know-how but especially resistance. The traditional way is to blame the blue-collars for the disturbing circumstances but in modern times the wind has changed its course where the managers themselves can be a contributor for implementation failures. Therefore, the aim of the research is to investigate what advantages that can be obtained by implementing a certain change initiative. Furthermore, to determine where resistance occurs and how to eliminate or reduce them. The change initiative in this research is implemented by conducting a case study in a Small Medium Enterprise (SMEs), where the main goal is to reduce the changeover time of a machine, by finding improvement suggestions using the Single Minute Exchange of Die (SMED) methodology. The results generated several improvement opportunities and gave an indication that there is a huge potential for improvements and elimination of waste during a typical changeover. The positive outcomes of implementing these improvement opportunities could theoretically reduce the changeover time, which directly reduces the overall cost but higher responsiveness, flexibility and efficiency can also be obtained. However, the evidence tells a story where the organization could experience obstacles during the implementation of the improvement suggestions, due to several factors. Surprisingly, the evidence points out that one root problem for resistance is difficulties of describing the underlying reason of the change initiative to the blue-collars. Moreover, there is in fact resistance and lack of awareness of the SMED methodology among the blue-collars and the managers, where fear of the unknown is another root problem for resistance.

Made available in DSpace on 2015-03-05T17:05:27Z (GMT). No. of bitstreams: 0 Previous issue date: 27 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / Esta dissertação apresenta uma proposta de método para elaboração de um sistema de indicadores industriais. O método é proposto visando estabelecer um alinhamento entre as dimensões competitivas oriundas da estratégia de produção e de sistemas de produção baseados nos conceitos, métodos e técnicas do Sistema Toyota de Produção e da Teoria das Restrições. A pesquisa tem como base metodológica o design research, estruturado em cinco fases: conscientização do problema, sugestão, desenvolvimento do artefato, avaliação e conclusão. O método sugerido para a elaboração do sistema de indicadores consiste em oito etapas: análise do ambiente industrial; identificação das práticas de gestão da produção utilizadas na empresa; análise do desdobramento da estratégia de negócios da empresa nos objetivos específicos da área industrial; elaboração de uma proposta inicial do conjunto de indicadores a ser adotado; detalhamento dos indicadores; validação do conjunto de indicadores proposta final do conjunto de indicadores e; mon

Submitted by JOSIANE SANTOS DE OLIVEIRA (josianeso) on 2018-04-26T15:00:14Z No. of bitstreams: 1 Guilherme Bacim_.pdf: 15496221 bytes, checksum: 753345aa27e543f77ece6c2dbf229575 (MD5) / Made available in DSpace on 2018-04-26T15:00:14Z (GMT). No. of bitstreams: 1 Guilherme Bacim_.pdf: 15496221 bytes, checksum: 753345aa27e543f77ece6c2dbf229575 (MD5) Previous issue date: 2018-02-27 / CAPES - Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / Este estudo de caso trata da avaliação da utilização das melhores práticas da Engenharia de Produção na indústria naval, tendo como pano-de-fundo o Estaleiro Atlântico Sul (EAS). Trata-se de um estudo de caso descritivo e explanatório. O trabalho descreve a trajetória evolutiva do sistema de produção do EAS, caracterizando-o em três fases distintas. Na Fase I, que se inicia em 2008 e se estende até julho 2014, identifica-se uma significativa influência dos fatores históricos da produção naval no Brasil que teve forte influência do paradigma Taylorista/Fordista, e pode ser sintetizado pelo fato de que a produção de navios era percebida enquanto uma ´obra´ com a gestão das diversas ´disciplinas´. A Fase II, que ocorreu entre julho de 2014 e janeiro de 2016, constituiu-se em uma etapa de transição que teve como elemento central o objetivo de modificar a cultura organizacional da empresa, o que foi efetivado através da adoção de conceitos tais como: 5S, mini fábricas e Kaizens com foco na melhoria dos fluxos produtivos e qualidade focada no processo. Já a Fase III, que inicia em janeiro de 2016, tem como evento crítico a criação de uma maquete em escala real do EAS que objetiva criar uma visão holística da empresa e do sistema de produção. A Fase III tem como embasamento teórico o Sistema Toyota de Produção e a Teoria das Restrições (TOC), tendo sido realizado uma importante modificação conceitual no que tange a percepção do ´objeto de trabalho´ ao longo de todo o sistema produtivo do EAS. As modificações que ocorreram, sob a égide e foco na Função Processo, foram centrais para a criação e melhoria dos fluxos produtivos em todo o sistema de produção. Visando a sustentação das mudanças ocorridas na Fase III, ocorreu uma ampla reformulação no modelo de gestão com a criação do conceito de Fábricas (Blocos, Pintura e Edificação) que passaram a ter gestores específicos responsáveis pelas melhorias incrementais e radicais dos fluxos produtivos. Além disso, foram realizadas ações no que tange à Função Operação: i) implantação do conceito de Gestão do Posto de Trabalho nas máquinas restritivas do corte; ii) gerar várias linhas de produção utilizando o conceito de box, com uma visão mais geral de fluxo oriundo da ótica do Tambor/Pulmão/Corda da TOC, com a utilização intensiva do conceito de Operação-Padrão para o dimensionamento dos mesmos. Ainda, através de um relatório de uma consultoria coreana, foi possível entender um conjunto de gaps existentes entre o modelo de sistema de produção atualmente adotado na empresa em estudo e o benchmarking coreano. A partir desta perspectiva evolucionária histórica de desenvolvimento do sistema produtivo do EAS, o trabalho propõe a adoção de uma série de boas práticas no intuito de aprimorar os processos na empresa em estudo. Finalmente, a título de conclusão, a aplicabilidade dos conceitos de engenharia de produção na indústria naval, tem impacto direto em termos das melhorias econômico-financeiro da empresa. / This case study deals with the evaluation of the use of the best practices of Production Engineering in the naval industry, having as background the Estaleiro Atlântico Sul (EAS). It is a descriptive and explanatory case study. The project describes the evolutionary trajectory of the EAS Production System, characterizing it in three distinct phases. In Phase I, which begins in 2008 and extends until July 2014, it is identified a significant influence of the historical factors of the naval production in Brazil that had strong influence of the Taylorist / Fordist paradigm, and can be synthesized by the fact that the production of ships was perceived as a ' construction ' with the management of the several ‘disciplines’. Phase II, which occurred between July 2014 and January 2016, constituted a transition phase that had as its central element the goal of modifying the organizational culture of the company, which was accomplished through the adoption of concepts such as: 5S, mini factories and Kaizens focused on improving production flows and process-focused quality. And in Phase III, which begins in January 2016, has as a critical event the creation of a full-scale EAS model that aims to create a holistic view of the company and the production system. Phase III has as its theoretical basis the Toyota Production System and the Theory of Constraints (TOC), and an important conceptual modification was made regarding the perception of the 'work object' throughout the EAS production system. The changes that occurred under the aegis and focus on the Process Function were central to the creation and improvement of production flows throughout the production system. In order to sustain the changes that occurred in Phase III, there was a broad reformulation in the management model with the creation of the concept of Factories (Blocks, Painting and Edification) that started to have specific managers responsible for the incremental and radical improvements of the productive flows. In addition, actions were taken with respect to the Operation Function: i) implementation of the concept of Workstation Management in the restrictive cutting machines; ii) generate several production lines using the box concept, with a more general view of flow from the TOC Drum / Buffer / Rope perspective, with the intensive use of the Standard Operation concept for their design. Also, through a report from a Korean consultancy, it was possible to understand a set of gaps between the production system model currently adopted in the company under study and the Korean benchmarking. From this evolutionary historical perspective of the development of the EAS production system, the paper proposes the adoption of a series of good practices in order to improve the processes in the company under study. Finally, as a conclusion, it seems possible to affirm the adherence and applicability of the concepts of production engineering in the naval industry, and its application has a direct impact in terms of the company's economic and financial improvements

The customer's taste is with the transition with constant time ¡A space¡A as the order pours into constantly¡A what an attitude the manufacturing plant is!¡A the flexible company quick in response turn into the existence ways of enterprises in the future¡A and under facing and producing state that must be expanded¡A how to set up production line and efficient duplicating the productive attitude fast fast¡A is it reach quantity produce quality that customer want fast ¡A must is it is it waste carry on procedure transformation to reduce to come through NPS (New Production Skill ) to come. This research is mainly to visit the arrangement which refers to the theory of relevant documents to review and study through the executive inside the company¡A to understand the company understand the themes studied from the doing in the test amount factor of expanding the factory¡A set up NPS to be flat to take production line while being accurate ¡A utilize relevant step in accordance with follow ¡A make similar industry to establish NPS production line have one procedure way in accordance with following fast future.

六標準差（Six Sigma）為目前最受矚目與重視的品質活動，而精實生產方式（Lean Production System）係以及時化（Just-In-Time, JIT）及自働化（Jidohka）兩大概念，所發展出來的合理化生產系統。此二者俱以變異為基礎的思考（Variation-based Thinking），協助企業改善流程、提昇品質、生產力與競爭地位，其整合並被視為下一波管理思潮的新趨勢。 此外，若論及產業特性，服務產業有別於製造業，其特有的服務（Service）、交易業務（Transaction）與其他非製造性（Non-Manufacturing）流程，往往存在更多浪費與更多的改善機會，卻更為強調顧客滿意經營。 本研究鑑於研究缺口與實務發展之需，提出六標準差與精實生產方式應用於服務業之整合模式（Lean Six Sigma for Service，LS3）。本模式以精實生產方式減少內部浪費，並以六標準差導向顧客滿意之追求，不但兼顧企業內部與外部顧客之觀點，亦兼顧精實速度與六標準差之高品質。 / “Six Sigma” is one of the most popular quality initiatives recently. “Lean Production System” is the world famous production system developed and practiced by Toyota mobile company for a long time. It based on two concepts: “Just-In-Time” and “Jidohka”. Both two are based on the variation thinking to improve business process, enhance quality, production and competitive position. Besides, the integration of them is viewed as a new trend in the next management wave. Moreover, regarding to the industry characteristics, service industry is quite different from manufacturing industry. Even though there are more wastes and improvement opportunities, the application of Six Sigma, Lean Production System or their integration in service industry is quite few neither in literatures nor practice. This research proposes the Lean Six Sigma integration model based on the research gap and the practical need, and then adapt it for service industry. The model is named as “Lean Six Sigma for Service (LS3)” in this research. It balances the viewpoints of internal and external customers, and gives consideration to the Lean speed as well as Six Sigma high quality. Also, this research tries to contribute to the enhancement of management technology. / 目 錄 中文摘要………………………………………………………………………………I 英文摘要………………………………………………………………………………Ⅱ 誌謝……………………………………………………………………………………Ⅲ 目錄……………………………………………………………………………………Ⅳ 表目錄…………………………………………………………………………………Ⅶ 圖目錄…………………………………………………………………………………Ⅷ 第一章 緒 論…………………………………………………………………………1 1.1 研究背景與動機………………………………………………………………1 1.2 研究目的………………………………………………………………………4 1.3 研究範圍與限制………………………………………………………………5 1.4 研究方法………………………………………………………………………6 1.5 研究架構………………………………………………………………………7 第二章 文獻探討…………………………………………………………………8 2.1 六標準差………………………………………………………………………8 2.1.1 六標準差之發展沿革………………………………………………………8 2.1.2六標準差之定義與各家說法………………………………………………12 2.1.3 六標準差之組織架構及人員角色…………………………………………17 2.1.4 六標準差之改進循環………………………………………………………21 2.1.5 六標準差主要之八大工具…………………………………………………27 2.1.6 六標準差之推行現況………………………………………………………29 2.1.7 六標準差之運作特點………………………………………………………30 2.2 精實生產方式…………………………………………………………………31 2.2.1 精實生產方式之發展沿革………………………………………………31 2.2.2精實生產方式之定義…………………………………………………….34 2.2.3 精實生產方式之構成要素………………………………………………34 2.2.4 精實生產方式之推展步驟………………………………………………40 2.2.5 精實生產方式之運作特點………………………………………………42 2.3服務業…………………………………………………………………………46 2.3.1 服務業之定義……………………………………………………………46 2.3.2 服務業之特性……………………………………………………………48 第三章 模式建構…………………………………………………………………52 3.1 精實六標準差應用於服務業之綜觀（LS3 Overview）……………………52 3.2 導引階段（Lead Phase）……………………………………………………………56 3.3 研究階段（Study Phase）……………………………………………………………65 3.4 流暢階段（Smooth Phase）…………………………………………………………70 3.5 維持階段（Sustain Phase）…………………………………………………………73 第四章 模式驗證.…………………………………………………………………81 4.1 問卷對象…….………………………………………………………………81 4.2 專家意見…….………………………………………………………………83 第五章 結論與建議…………………………………………………………………84 5.1 研究結論……………………………………………………………………84 5.2 研究貢獻……………………………………………………………………85 5.3 後續研究建議………………………………………………………………86 參考文獻……………………………………………………………………………87 附錄A 專家訪談調查函……………………………………………………………93 附錄B 專家訪談問卷內容…………………………………………………………94 表 目 錄 表 2.1 六標準差的發展階段………………………………………………………12 表 2.2 標準差換算表………………………………………………………………14 表 2.3 六標準差方法論DMAIC………………………………………………………22 表 2.4 六標準差設計方法論DMADV……….………………………………………23 表 2.5 六標準差「工具的21個整合步驟：研發流程」…………………………25 表 2.6 豐田生產系統之「實驗」……………………………………………………44 表 3.1 LS3之內容要項與工具……………………………………………………54 圖 目 錄 圖 1.1 研究流程圖………………………………………………………………6 圖 2.1 製程中心飄移1.5標準差的情形………………………………………13 圖 2.2 典型的六標準差組織圖.…………………………………………………17 圖 2.3 執行六標準差之八大步驟…….…………………………………………27 圖 2.4 六標準差之八大工具…..…………………………………………………28 圖 2.5 精實生產方式五大主要要素…….………………………………………36 圖 2.6 消除浪費要素……………………………………………………………37 圖 2.7 全面品質要素………………………………………………………………38 圖 2.8 人員準備要素………………………………………………………………39 圖 3.1 LS3運作架構圖………………………………………………………………53 圖 3.2 LS3運作模式之工具總覽……………………………………………………55 圖 3.3 導引階段之使用工具………………………………………………………57 圖 3.4 研究階段之使用工具………………………………………………………66 圖 3.5 流暢階段之使用工具………………………………………………………70 圖 3.6 維持階段之使用工具………………………………………………………74

The thesis deals with the application of Lean management in optimizing business processes, namely logistics processes. The author narrows the theoretical view as possible in today's practice to optimize the logistics processes in the real case study of a company. One of the theoretical foundations of modern Japanese approach based on Lean Management is called Toyota Production System. The practical focus of the work lies in analysis of the actual deployment of optimization in company specialized in hotel industry. Finally, thesis evaluates the success of optimization in the organization. The author has proposed some practical pieces of advice and techniques to approach optimization in near future.