En el presente trabajo de investigación, se analiza la Supply Chain del proceso de reparación de componentes de una empresa de servicio especializada en el tren de fuerza de maquinaria pesada, con el propósito de mejorar su Lead Time, dado que el resultado actual, impacta negativamente en los plazos de entrega del servicio comprometido y consecuentemente la insatisfacción de los clientes. El indicador de lealtad de los clientes NLS (Net Loyalty Score), en continuo decremento, implica un riesgo para la sostenibilidad y el crecimiento de la empresa, por lo que había que tomar acciones. El estudio levanta información desde la recepción, hasta la salida de los motores y transmisiones; recoge data de los tiempos de entrega e información de Focus Group con el personal de taller; se utiliza herramientas Lean como el diagrama de Ishikawa y Pareto, los cuales permiten discriminar las causas principales. Asimismo, el Value Stream Map (VSM) del proceso actual, permitió identificar una oportunidad de mejora relevante para llevar el Lead Time de la reparación de motores de 37.5 a 30.5, colocando un Supermarket del componente crítico – Short Block (Kanban). Por otra parte, la implementación de ciertos activos de taller (SMED) ayudó a mejorar el Lead Time en el VSM futuro. / In this research work, the Supply Chain of the component repair process of a service company specialized in the power train of heavy machinery is analyzed, with the purpose of improving its Lead Time, given that the current result impacts negatively in terms of delivery of the committed service and consequently customer dissatisfaction. The continually decreasing NLS (Net Loyalty Score) customer loyalty indicator implies a risk to the sustainability and growth of the company, so actions had to be taken. The study gathers information from the reception to the exit of the engines and transmissions; collects data on the delivery times and information of Focus Group with the workshop staff; Lean tools such as the Ishikawa and Pareto diagram are used, which allow discriminating the main causes. Likewise, the Value Stream Map (VSM) of the current process, identified a relevant improvement opportunity to bring the Lead Time of engine repair from 37.5 to 30.5, placing a Supermarket of the critical component – Short Block (Kanban). On the other hand, the implementation of certain taller assets (SMED) helped improve Lead Time in the future VSM. / Trabajo de investigación

[pt] A aplicação dos conceitos do lean é uma prática originada na indústria automotiva utilizada inicialmente em áreas produtivas, permitindo ganhos de produtividade, através da redução de desperdícios nos fluxos de processo. Após o sucesso comprovado da utilização do lean em áreas produtivas, as organizações têm expandido a utilização deste conceito para outras áreas. O objetivo desta dissertação é aplicar a abordagem lean na revisão do fluxo de materiais de um almoxarifado, de uma empresa fabricante de equipamentos para o setor de óleo e gás. A metodologia utilizada tem dois componentes: uma revisão sistemática da literatura sobre o conceito lean e a pesquisa-ação através de um protocolo baseado em um modelo proposto para aplicação de estudos de caso em pesquisa-ação. Este trabalho descreve o processo de aplicação do lean. Os resultados alcançados foram a demonstração da viabilidade da aplicação dos princípios lean no almoxarifado, a identificação do fluxo de valor e do 5S como as principais ferramentas de implementação, uma redução significativa dos tempos de fluxo do almoxarifado. As barreiras encontradas foram a concorrência do tempo das pessoas entre a pesquisa-ação e suas atividades rotineiras e o baixo envolvimento inicial dos setores interface com o almoxarifado (e.g., planejamento, compras e produção). Uma proposta baseada no mapa de fluxo de valor futuro para o fluxo de materiais no almoxarifado, migrando do modelo tradicional empurrado para o modelo enxuto, foi apresentada à empresa e está sendo considerada para implementação. / [en] The application of lean concepts is a practice originated in the automotive industry initially used in manufacturing areas, enabling productivity gains by reducing waste in the process flows. After the proven success of using lean in manufacturing areas, organizations have expanded the use of this concept to other areas. The aim of this work is to apply the lean approach in the review of the flow of materials from a warehouse in equipment s manufacturer for the oil and gas sector. The methodology used has two components: a systematic review of literature on the lean concept and action research through a protocol based on a proposed model for application of case studies on action research. This dissertation describes the lean application process. The results achieved to date demonstrate the feasibility of the application of lean principles in the warehouse, identifying the value stream and 5S as the main implementation tools, and a significant reduction in warehouse s flow lead times. Barriers were found as competition of people s time between action research and their routine activities and the low initial involvement of sectors interfacing with the warehouse (eg, planning, purchasing and production). A proposal based on the map of future value stream to the flow of materials in the warehouse, migrating from traditional pushed to lean model, was presented to the company and is being considered for implementation.

This article presents a proposal for applying lean manufacturing concepts to a sewing production line from a typical apparel company that produces knit garments for export, in order to reduce lead time, in-process inventory and processing delays. Using value stream map and seven wastes approach, the paper presents and analyzes the current configuration of a typical sewing line, identifying the most important wastes throughout the process. It proposes a lean production system consisting of five elements, aimed at reducing the main factors of waste caused by the conventional production system: a) reducing the size of the line, b) implementation of a unit production system), c) implementation of a line-controlled load system (pull system), d) implementation of group incentives, and e) increasing delivery frequency of outgoing garments to finishing department. As a result, the proposed model is able to reduce lead time, cycle time, in-process inventory and unnecessary movements.

The purpose of this thesis is to study how the interaction between lean and sustainability theories works in the logistics department of a manufacturing company. The research has been developed by applying a Value Stream Map with adjusted factors to help to map the flow of materials throughout the department. Literature review have shown connections between lean and sustainability, but it has yet to be evaluated focusing on the logistics department. After the analysis of the current state of the factory under the two methodologies, an improved layout has been proposed. The results have concluded that Value Stream Map is a valuable tool to understand the performance of a company under both theories. The addition of the sustainability perspective to the lean tool has created the opportunity to evaluate more factors, which lead to more opportunities in the proposition of future state for the flow of material. It gives also the possibility to extend the “continuous improvement” (Kaizen) principle of lean to the sustainability areas in an efficient way.

Orientador: Paulo Corrêa Lima / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-18T11:47:36Z (GMT). No. of bitstreams: 1 Nicodemo_LuizGustavoGrossi_M.pdf: 2943348 bytes, checksum: 500fcfbed0c132f1e779eebf78bca027 (MD5) Previous issue date: 2005 / Resumo: Este trabalho apresenta uma metodologia para o direcionamento de projetos de melhoria nas empresas com base nas ferramentas do Sistema Toyota de Produção. Muito esforço têm sido despendido pelas empresas para alcançar resultados significativos em projetos de melhoria justamente pela não utilização de métodos estruturados de direcionamento destes projetos. O modelo metodológico proposto utiliza a integração entre o Mapa de Fluxo de Valor, o Balanced Scorecard, e o guia de produção enxuta da empresa como ferramenta para garantir a melhor relação possível entre custo e benefício alcançado nos projetos de melhoria. A validação do modelo se dá através de um projeto de implementação coordenado pelo autor, que utiliza esta metodologia durante mais de um ano em uma empresa de autopeças, e ao final do trabalho apresenta os ganhos referentes à aplicação do método / Abstract: This work presents a methodology to drive business improvement projects based on Toyota Production System tools. A lot of efforts are being spent by the companies to reach significant results on improvements projects because they do not utilize structured methods to drive these projects. The methodological model proposed uses the integration between the Value Stream Map, the Balanced Scorecard, and the Lean Production Guide of the company as a tool to assure the best possible relation between cost and reached benefits on improvements projects. The validation of the model occurs through an implementation project coordinated by the author, who applied this methodology for more than a year in an auto parts company and at the end presents the gains related to the application of the method / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

The diploma thesis deals with the problematics of lean production in a selected company. The analytical part includes the introduction of the company and the analysis of the current state with using lean manufacturing tools to optimize material flows. The thesis is divided into four parts. The first part describes the objectives and methodology, followed by the theoretical basis of the work and analysis of the current state of the company. The final part includes suggestions of possible solutions leading to elimination or improvement of identified problems.

Arbetet har utförts vid Tekniska Högskolan i Jönköping där en studie har genomförts i samarbete med Kitron AB som är ett elektroniktillverkande företag. Kitron strävar efter att reducera kapitalbindningen för att vara kostnadseffektiva och därmed hålla hög konkurrenskraft. Studiens syfte var att identifiera de aspekter som påverkar företagets kapitalbindning och ta fram åtgärdsförslag för att minska kapitalbindningen som orsakas av materialflödet för ett av Kitrons kundprogram inom medicinteknik. Olika metoder användes för att samla in data gällande materialflödet. För att finna åtgärder analyserades materialflödet utifrån insamlad teori och genomförd värdeflödesanalys. Studien resulterade i identifiering av ett antal aspekter som påverkar kapitalbindningen och utifrån de togs åtgärder fram. De rekommenderade åtgärderna grundas i teori om Lean production. Åtgärdsförslagen bidrar till att effektivisera materialflödet och minimera den totala ledtiden för att reducera kapitalbindningen. Ett effektivare materialflöde kan uppnås genom att producera enligt principerna inom just in time och minimera slöseri. God samverkan med de kunder och leverantörer som påverkar materialflödet är också önskvärt. Den produktstruktur som Kitron utgår ifrån kan även anpassas efter produktionen för att minimera produktionsledtiden. Sammanfattningsvis krävs en kortare ledtid för att reducera kapitalbindningen inom det studerade kundprogrammet. Med hjälp av en del av de presenterade åtgärdsförslagen skapades ett idealt materialflöde som innebar reducering av produktionsledtiden med 15,5 dagar. Detta skulle medföra en reducering av kapitalbindningen med ungefär 454 000 kronor. / This project has been carried out at Jönköping University of Technology. The study has been executed in collaboration with the electronics manufacturing company, Kitron AB. Kitron aims to reduce the capital tied up to be cost efficient and improve the competitiveness. The purpose with this study was to identify the aspects that affect the company´s capital tied up and also find solutions to reduce the capital tied up caused by the material flow. A case study was executed at the company where the study was delimited to one specific customer of Kitron that make biomedical technology. Different methods were being used to gather data which has later been analyzed based on the theoretical framework. To find the solutions and identify the material flow an analyze was executed from theoretical aspects and a value stream map.  The study resulted in identification of several aspects that affect the capital tied up. From these aspects, solutions were found. The recommended solutions are based on theory about lean production. The solutions contribute to a more efficient material flow and help reduce the total lead time to enable a lower capital tied up. A more efficient material flow can be achieved by producing according to the principles of just in time and by reducing waste. It is preferable to cooperate with customers and suppliers that affect the material flow to improve it. The product structure can be arranged differently to enable a shorter production lead time. In conclusion, a shorter lead time is necessary to reduce the capital tied up concerning the studied customer. An ideal material flow was created by using some of the suggested solutions, which resulted in a shorter production lead time by 15,5 days. This would also contribute to a reduction of the capital tied up with 454 000 SEK.

Companies are constantly seeking new ways to increase their efficiency and flexibility to be able to meet the market demand, industry 4.0 has provided companies with new tools that enables them to better track the performance of a process and more easily optimise it. In a high mix and low volume manufacturing process a lot of inefficiencies are prone to occur due to the high variety. A simulation can be a very beneficial tool to use in the optimisation of a manufacturing process. In a simulation a digital twin of the physical process is constructed to replicate the real-world results, the simulation can then be used to test how changes to the process affects the desired performance objectives. The purpose of this study was to use a simulation to optimise the process by increasing output and reduce lead time as well as increase the visual presentation of the process. The purpose was fulfilled by a review of literature on the subject, interviews, observations and a document study before a simulation model and value stream map was constructed. The bottleneck analysis and the value stream map highlighted a few inefficiencies in the process that was solved by implementing a few solutions that would improve the balance of the process and increase output and decrease lead time. A visual presentation tool was also developed to calculate the expected lead time for a new order and show how the flow of orders would develop in the near future.

There is a gap in the research regarding applications of Lean tools in the wood fiber supply chain. A Value Stream Map (VSM) tool that focused on identifying Lean waste in logistic operations was developed and applied to three case study firms: a paper mill, a sawmill, and a logger. Using the VSM tool an absence of structured methods to select and assess suppliers was found, which promotes a fluctuating environment for suppliers. Therefore, a tool that implements a hierarchy system to categorize suppliers was developed, verified and validated. Through the use of the VSM implementation the author found a lack of information sharing between supply chain stakeholders, which causes a reactive environment for the industry. Improvements in wood flow planning, tract allocation, truck scheduling, and communication were projected as a future state of the system. The annual potential savings by implementing the projected improvements in the total cost were as follows for the paper mill, the sawmill, and the logger respectively: $306,232, $312,085, $756,504. As a result of the findings obtained through the VSMs, a supplier selection model was designed. The tool was implemented into software for the wood industry. The tool was then verified and validated. The verification process consisted of comparing the output through previously known results and was performed through seven interviews with different stakeholders. The appropriate application of the supplier selection tool improves the way in which companies in the wood industry select and assess their suppliers and guarantee that the best alternatives are selected. / Master of Science / In the wood fiber supply chain, integration between different parties within a supply chain has proven to be a difficult task. An innovative lean-logistics tool value-streamed map (VSM) was developed to evaluate the current and future state of a supply chain Once the tool was developed it was used to map the wood fiber supply chain, determine and measure key performance metrics, calculate the cost of logistics operations, and identify potential sources of waste. Three case studies representing common wood fiber supply chains were conducted to develop three current VSMs for selected value streams. The lack of communication between supply chain partners was determined to be the most significant source of waste in all three cases. Lack of communication could lead to idle equipment, unnecessary waiting times, excessive inventories, overproduction, and excessive transportation and movement. As a result of the findings obtained through the VSMs, which revealed the absence of structured methods to select and assess suppliers, a supplier selection model was designed. The tool was implemented into software for the wood industry. The tool was then verified and validated. The verification process consisted of comparing the output through previously known results and was performed through seven interviews with different stakeholders. The appropriate application of the supplier selection tool improves the way in which companies in the wood industry select and assess their suppliers and guarantee that the best alternatives are selected, thus increasing the chance of a successful relationship and increasing the value that the company gets from its supplier base.

This dissertation reports the investigation and combination of optimization methodologies and the result of implementing them within a production environment. A literature survey was conducted on the optimization methodologies Lean Manufacturing and theory of constraints (TOC). A number of production optimization methodologies were studied and considered for application to the case study organisation. Due to the small size and relative simplicity of the operation, these methodologies had to be simplified and combined into a more relevant form. A refractory manufacturer was used as a case study for the investigation into the optimization of the dry batch plant. Lean Manufacturing and TOC are optimization methodologies that could be employed to optimize the dry batch plant. Tools from these methodologies were used to investigate problems identified within the production process that were causing the batching plant to perform non-optimally. A time and motion study was conducted and a process flow chart was created to understand the production process. Wasteful activities were identified using a value stream map and a flow process chart was used to visualise the movement within the production process. A 5-Why analysis was conducted to determine the root causes. An optimization plan was created to eliminate the wasteful activities and the operational measures, that is throughput, inventory and operating expense, were used as to determine what the effect the optimization plan would have on the wasteful activities (Lean Manufacturing) found within the batching plant and the organisation. The results of the combined effect of the optimization plan are discussed focusing on the improvements in the operational measures and the increase in profit from sales. Future research is suggested to improve the benchmarking of the optimization plan and any future improvements that the organisation might implement. / MSc (Development and Management Engineering), North-West University, Potchefstroom Campus, 2015