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

Submitted by Alison Vanceto (alison-vanceto@hotmail.com) on 2017-02-17T12:11:12Z No. of bitstreams: 1 DissAVA.pdf: 5462126 bytes, checksum: dd39f79a2b4214655f4466707c8f0fab (MD5) / Approved for entry into archive by Ronildo Prado (ronisp@ufscar.br) on 2017-03-09T19:27:15Z (GMT) No. of bitstreams: 1 DissAVA.pdf: 5462126 bytes, checksum: dd39f79a2b4214655f4466707c8f0fab (MD5) / Approved for entry into archive by Ronildo Prado (ronisp@ufscar.br) on 2017-03-09T19:27:26Z (GMT) No. of bitstreams: 1 DissAVA.pdf: 5462126 bytes, checksum: dd39f79a2b4214655f4466707c8f0fab (MD5) / Made available in DSpace on 2017-03-09T19:39:36Z (GMT). No. of bitstreams: 1 DissAVA.pdf: 5462126 bytes, checksum: dd39f79a2b4214655f4466707c8f0fab (MD5) Previous issue date: 2016-08-30 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / This research aims to propose and simulate various scenarios based on the principles of Lean Construction aiming to run a reticulated structure of reinforced concrete residential building with multiple floors within the stipulated time in its planning, taking as within seven days (takt time) to completion. The research strategies adopted included a literature review, identification of application opportunities of the principles of Lean Construction, the development of computational model that represented the studied structure, as well as the various scenarios and their simulation. The opportunities of application of the Lean Construction principles were identified through evaluation of Value Stream Mapping (VSM) and Line of Balance (LB). Five scenarios were prepared, the first being the reference, from which were simulated improvements with the use of simulation software ProModel® in 2014. Each version simulation carried out with consideration of an improvement based on the principles of Lean Construction, resulted in the reduction of lead time, converging in the simulation of the latter scenario, for a little higher than the takt time. As a partial indicator of simulation scenarios were evaluated the average cycle times, drive, hold and conversion data they extracted the software used. A comparison of time between the first scenario, depicted as representing the simple observation of the site plus the inherent variability and the latter scenario, characterized by cumulative application of the principles of lean construction, showed that the cycle time returned a reduction in the order of 29% handling increased by 105%, the expected reduced by 54% and the conversion time reduced by 26%. The main result achieved in the fifth scenario was a Lead Time 66.2 hours production. It can be seen that the use of the VSM and simulation provides a clear and concise communication on lean approaches and thus allows the understanding and continuing evolution of Lean concepts. / Este trabalho tem por objetivo propor e simular vários cenários com base nos princípios da Construção Enxuta objetivando executar uma estrutura reticulada de concreto armado de uma edificação residencial de múltiplos pavimentos dentro do prazo estipulado no seu planejamento, tendo-se como prazo de sete dias (takt time) para sua finalização. As estratégias de pesquisa adotadas incluíram a revisão bibliográfica, a identificação das oportunidades de aplicação dos princípios da Construção Enxuta, a elaboração do modelo computacional que representou a estrutura estudada, assim como os vários cenários e sua simulação. As oportunidades da aplicação dos princípios da Construção Enxuta foram identificadas por meio da avaliação do Mapeamento do Fluxo de Valor (MFV) e Linha de Balanço (LB). Foram elaborados 5 cenários, sendo o primeiro o de referência, a partir do qual foram simuladas as melhorias com uso do software de simulação ProModel® na versão 2014. Cada simulação realizada, com a consideração de uma melhoria com base nos princípios da Construção Enxuta, resultou na redução do lead time, convergindo, na simulação do último cenário, para um valor pouco superior ao takt time. Como indicador parcial dos cenários da simulação, foram avaliados o valor médio dos tempos de ciclo, movimentação, espera e conversão, dados estes extraídos do software utilizado. A comparação dos tempos entre o primeiro cenário, caracterizado como a representação da simples observação do canteiro acrescido sua variabilidade inerente, e o último cenário, caracterizado pela aplicação cumulativa dos princípios da construção enxuta, mostrou que o tempo de ciclo retornou uma redução na ordem de 29%, a movimentação aumentou em 105%, a espera reduziu em 54% e o tempo de conversão reduziu em 26%. O principal resultado alcançado no quinto cenário, foi um Lead Time de produção de 66,2 horas. Pode-se observar que o uso do MFV e da simulação fornece uma comunicação clara e concisa sobre abordagens enxutas e, desta forma, permite a compreensão e a evolução contínua dos conceitos Lean.

PSA Peugeot Citroën, a French automaker, has one plant in Brazil, located in Porto Real, Rio de Janeiro. This factory mounts 29 vehicles / hour of eight different models, four models of Peugeot and Citroën brand four. This great variety of models generates complexity in the production process and wide range of parts. This study aims to analyze the impact of diversity, illustrate wasteful standard concept of 3MUs (MUDA, MURI, MURA) and present a study of reducing overall diversity. This will be used to apply the tools and techniques of `Lean Manufacturing Concept. The Lean production system, which basically seeks to eliminate waste, presents several concepts that can and should be applied in studies of eliminating diversity. Among the concepts that can be used stand out studies Time and Methods, SMED, 5S, Kanban, Value Stream Mapping and Kaizen and Poka-Yoke. Through analysis of cases will demonstrate that reducing the diversity of parts and reduce costs, avoid waste and adding a number of benefits, impacts directly on the entire production chain of the automaker. The reduction of diversity interferes with logistics (transport, handling, storage, control), quality (robustness of process variability), production (surface, rework), systems (complex document base, variety of systems), engineering (equipment, investments, solutions) and suppliers (setups, inventories). Therefore, this work is of extreme importance and relevance for companies with a high level of competitiveness, such as assemblers, stay ahead in the job market and offer the best value for money offers. / A PSA Peugeot Citroën, montadora de origem francesa, possui uma única fábrica no Brasil, localizada em Porto Real, Rio de Janeiro. Essa fábrica monta 29 veículos/hora de oito modelos distintos, sendo quatro modelos da marca Peugeot e quatro da marca Citroën. Essa grande variedade de modelos gera uma complexidade no processo produtivo e grande diversidade de peças. Esta dissertação tem como objetivo analisar o impacto da diversidade, exemplificar os desperdícios no padrão do conceito dos 3MUs (MUDA, MURI, MURA) e apresentar um estudo de redução da diversidade geral. Para isso, será utilizada a aplicação das ferramentas e técnicas do `Lean Manufacturing Concept. O sistema de produção Lean, que basicamente busca a eliminação de desperdícios, apresenta diversos conceitos que podem e devem ser aplicados nos estudos de eliminação da diversidade. Entre os conceitos que podem ser utilizados, destacam-se Estudos de Tempos e Métodos, SMED, 5S, Kanban, Mapeamento de Fluxo de Valor e Poka-Yoke e Kaizen. Através da análise de casos, se mostra que a redução da diversidade de peças, além de reduzir custos, evitar desperdícios e agregar uma série de benefícios, impacta diretamente em toda a cadeia produtiva da montadora. A redução da diversidade interfere na logística (transporte, movimentação, armazenagem, controle), na qualidade (robustez do processo, variabilidade), na produção (superfície, retrabalhos), nos sistemas (complexa base documental, variedade de sistemas), na engenharia (equipamentos, investimentos, soluções) e nos fornecedores (setups, estoques). Portanto, a presente dissertação é de extrema importância e relevância para que empresas com alto nível de competitividade, como as montadoras, permaneçam a frente no mercado de trabalho e ofereçam as melhores ofertas de custo-benefício.

Debido a la plusvalía del suelo y al incremento poblacional en los distritos Top de Lima, los proyectos inmobiliarios se diseñan con un mayor número de sótanos para poder cubrir la demanda de estacionamientos. Por lo que en la presente investigación vamos a emplear la herramienta Value Stream Mapping para optimizar el proceso de excavación masiva. El Value Stream Mapping es una herramienta empleada en la industria manufacturera que pertenece a la filosofía Lean Manufacturing, esta herramienta consiste en identificar el flujo de la cadena de valor de cierta actividad y mediante un gráfico tener una visión completa del flujo de trabajo y de todos los procesos involucrados. Mediante este mapeo resultará mucho más sencillo identificar los procesos que no aportan valor a la actividad para luego aplicar mejoras y poder optimizar el proceso de excavación masiva. Para analizar el proceso de excavación masiva se utilizaron datos obtenidos de tres proyectos ubicados en Lima cuyas profundidades de excavación fueron de 3 y 4 anillos. El mapeo de estado actual de estos proyectos nos permitió realizar un diagnóstico general e identificar los procesos con mayores tiempos no productivos. Finalmente, se elabora un mapa de estado futuro considerando la propuesta de mejora para el proceso de eliminación con pasamano de dos excavadoras, se implementa la propuesta de mejora en un cuarto proyecto con una profundidad de excavación de 6 anillos, con los resultados obtenidos se justifica que empleando la herramienta de Value Stream Mapping se puede optimizar el proceso de excavación masiva. / Due to the increase in land value and population growth in the top districts of Lima, real estate projects are designed with a greater number of basements to meet the demand for parking. Therefore, in this research we are going to use the Value Stream Mapping tool to optimize the massive excavation process. Value Stream Mapping is a tool used in the manufacturing industry that belongs to the Lean Manufacturing philosophy, this tool consists of identifying the flow of the value chain of a certain activity and by means of a graphic to have a complete vision of the workflow and all the processes involved. Through this mapping it will be much easier to identify the processes that do not add value to the activity and then apply improvements to optimize the mass excavation process. To analyze the mass excavation process, data obtained from three projects located in Lima with excavation depths of 3 and 4 rings were used. The current state mapping of these projects allowed us to make a general diagnosis and identify the processes with the longest non-productive times. Finally, a future state mapping is elaborated considering the improvement proposal for the two-excavator handrail disposal process, the improvement proposal is implemented in a fourth project with an excavation depth of 6 rings, with the results obtained it is justified that using the Value Stream Mapping tool the massive excavation process can be optimized. / Tesis

This diploma thesis is focused on the optimization of a specific process in the environment of the manufacturing company that supplies the components in the automotive and other industries. The theoretical part explains the principles and techniques of optimization of production processes and describes the placement of workplaces. The practical part of thesis analyzes the current state of the production process, identifies potential for improvements and proposes a new layout of workplaces. The project is then evaluated from both technical and economical viewpoint.

This thesis deals with the optimalization of production of the thermostat bulb K22 in Invensys Appliance Šternberk Ltd. company. It analyzes the manufacturing process and proposes its optimal solutions. This thesis also describes other possible solutions that contribute to efficient management of the lean enterprise. The main benefit of this thesis is in the reduction of required labor time for the manufacture of the thermostat and in the introduction of lean management of selected tools.

The aim of this thesis is to analyze the material flow in a company located at the second stage of the supply. Material flow is monitored in terms of logistics. The focus becomes reducing production lead times due to optimized inventory. In the theoretical section briefly summarizes the nature of material flow and the means used to optimize inventory. The content of the practical part is a detailed conflict of manufacturing and non-manufacturing operations, which will be the basis for possible suggestions to improve all material flow.

The subject of this diploma thesis is to improve the manufacturing of ISO standard valves using basic Lean manufacturing methods. Focus was at two levels, the macro level dealing with auxiliary processes for the whole manufacturing area and the micro level looking at removal of waste in the processes on one particular production cell.

En este trabajo se analiza el modelo de producción de una planta de extracción y procesamiento de materiales para la construcción del radio urbano de la ciudad de Lima, buscando identificar aquellos factores que afectan a su productividad. Mediante un análisis basado en el mapeo del flujo de valor de los procesos (value stream mapping) tomando en consideración tiempos, secuencia y flujos, se identificaron las restricciones del sistema, sus cuellos de botella y los trabajos no “contributorios”. Utilizando esa información, se individualizaron los procesos constitutivos y se identificaron sus problemas. Aplicando los métodos de la filosofía Lean, se evaluó que es posible modificar los factores de éxito como alcance, tiempo, costo y calidad. Esto permitiría lograr a corto plazo una mejora en la productividad de la empresa. Además, la incorporación de premisas guías de gestión de la calidad y gestión del mantenimiento pueden resultar en otras oportunidades de mejora. La propuesta desarrollada proporcionaría los siguientes beneficios para la empresa: identificación de las principales causas de las paralizaciones en la producción, mejora del registro, control y evaluación de los procesos, incremento en la vida útil de los equipos y maquinaria, y reducción de los tiempos en los procesos operativos. Una conclusión importante es que será el monitoreo periódico el que permitirá que la mejora en la productividad sea una constante en la empresa. / This work is devoted to the analysis of the production model of a construction materials extraction and processing plant of Lima City, identifying those factors that affect its productivity. By applying a value stream mapping analysis considering operation times, sequencies and streams, the main system restrictions were identified along with bottlenecks and non-contributing activities. This information allowed to identify each individual process and associated problems. By applying the Lean Method, it would be possible to modify the success factors such as reach, times, costs and quality, which would allow to improve the plant productivity in the short term. In addition, the inclusion of guidelines of quality control management and maintenance control management could represent novel opportunities for quality improvement. The proposal developed here would result in the following benefits for the company: identification of the main causes of stoppages in production, improvement of the record keeping, control and evaluation of processes, enhanced lifetime of equipment and machinery, and reduction in operational times. An important conclusion is that only by periodically monitoring the system a long-lasting company productivity improvement could be achieved. / Trabajo de investigación

Implementeringen av Leanverktyg i sågverksindustrin är fortfarande nyjämfört med andra industrier. Syftet med denna studie är därför att ökakunskapen om tillämpningen av Lean och se vilken effekt det har. Måletär att se vilka Lean-verktyg som är lämpliga för denna industri och hur dekan tillämpas. En kartläggning av fallföretagets nuvarande tillstånd skapasoch analyseras, och flera slöserier identifieras. Det undersöks också vilkaandra Leanverktyg som kan tillämpas effektivt. Ett TAK värde beräknasutifrån värdeflödesanalysen samt processens effektivitet. På grund avomständigheterna är våra resultat mycket missvisande och bättretillämpningar av Leanverktyg diskuteras. Som en följd av våraavgränsningar rekommenderas ytterligare forskning för att uppnå enbättre rapport. / The implementation of Lean tools in the sawmill industry is still new compared to the other industries. Therefore the purpose of this study is to increase the knowledge around the application of Lean and see the effect it has. The objective is to see which Lean tools are suited for this industry and how they can be applied. A map of the current state of the case company is created and analyzed, and several wastes are identified. It is also researched which other Lean tools can be applied effectively. An Overall equipment effectiveness value is calculated from the Value stream map as well as the process efficiency. Due to the circumstances our results are very misleading and better applications of Lean tools are discussed. As a consequence of our boundaries further research is advised to achieve a better report.