Trabalho realizado na Unicer e orientado pelo Paulo Texeira / Tese de Mestrado Integrado. Engenharia Industrial e Gestão. Faculdade de Engenharia. Universidade do Porto. 2013

Bakgrund: Volvo Cars Body Components (VCBC) tillverkar och levererar karosskomponenter till Volvo Cars. För sex år sedan påbörjade VCBC sin implementering av lean production. För att beräkna de kostnader som uppstår i produktionen använder VCBC produktkalkyler. Representanter vid VCBC anser att företaget har problem med höga plåtlager, överproduktion samt problem med att se kostnadssamband. Ett value stream där förbättringsmöjligheter finns är Flöde 1 vid VCBC. Enligt vad Maskell et al. (2011) påstår kan problemen vara effekter av kombinationen mellan lean production och produktkalkyler. Maskell et al. (2011) menar att företag bör beräkna kostnader på hela value stream vid lean production. En modell som gör det och som Maskell et al. (2011) menar att företag bör använda vid lean production är value stream costing. Syfte: Den här studien syftar till att identifiera de kostnader som bör ingå i en VSC-modell för VCBC. Vidare syftar studien till att, med hjälp av första problemformuleringen, beräkna vad den totala kostnaden för Flöde 1 skulle bli om VCBC tillämpar VSC. Studiens syfte är även att undersöka vad införandet av en VSC-modell skulle innebära för VCBC. Metod: Studiens angreppssätt är av kvalitativ art. Då studien har en intervenistisk forskningsstrategi där vi tillämpade aktionsforskning föll det sig naturligt att använda fallstudie som forskningsdesign. För insamling av data har vi använt dokument, arkivmaterial, intervjuer och direkta observationer. Slutsatser: De kostnader som bör ingå i en value stream costing-modell för VCBC är; fastighetskostnad, materialkostnad, avskrivningar, kapitalkostnader, personalkostnader, leasing & hyror samt IT-kostnader. Om VCBC tillämpar value stream costing skulle det resultera i att den årliga kostnaden för Flöde 1 blir; 3 277 524 kronor. Skulle VCBC implementera value stream costing hade det framför allt inneburit att VCBC hade fått en större förståelse för sina value stream, att det hade skapat ett bättre flöde samt att VCBC inte hade behövt spåra historisk data utan att uppföljning kan ske veckovis för att kunna göra förändringar innan det är för sent. Dessutom hade det inneburit att VCBC’s maskiner hade blivit värderade till kalkylmässiga värderingar så att den fysiska kapaciteten är bevarad, samt att genomsnittskostnaden per produkt hade uppgått till 70 kronor per styck istället för den VCBC kalkylerar med idag som är 98 kronor per styck. / Background: Volvo Cars Body Components (VCBC) manufactures and supply body parts for Volvo Cars. It is six years since VCBC began the implementation of lean production. VCBC is using traditional accounting methods to calculate the production costs. Some employees at VCBC consider that the company has problems with high stocks of raw material, overproduction, and trouble seeing relation between costs. One value stream where improvements can be made is at “Flöde 1” at VCBC. As Maskell et al. (2011) say that the problems might be a result from the effects of the combination between lean production and traditional accounting methods. Maskell et al. (2011) argue that costs in lean should be calculated for the entire value stream. A model that makes so and who Maskell et al. (2011) believes should be used in lean is value stream costing. Purpose: This study aims to identify the costs that should be included in a value stream costing-model for VCBC. Furthermore, the study aims to calculate the total cost for “Flöde 1” by using the first research question. Last the study will investigate what the value stream costing model would mean if VCBC includes the method in their lean work. Methodology: The study was performed by using a qualitative research method. Since we used a interventionist research in which we applied action science it was obvious to use case study as a research design. For data collection, we used documents, archival records, interviews and direct observations. Conclusions: The costs that should be included in a value stream costing model for VCBC are; property cost, material cost, depreciation, capital cost, labor cost, costs for leasing and IT cost. If VCBC apply value stream costing it will result in the annual cost for “Flöde 1” to be; 3 277 524 SEK. If VCBC would implement value stream costing it will primary mean that VCBC can get better understanding for their value streams and by this create a better flow. Furthermore, VCBC does not need to track historically data but instead follow-up on a weekly basis to make changes before it is too late. Another change for VCBC if they implement value stream costing is that they have to evaluate their machines so they keep the physical capacity in mind, and that the cost per product will be decreased from 98 SEK to 70 SEK.

Title: A case study for LORAMAX on supply chain strategy & production efficiency.  Limitations: Due to the sensitive nature of the information in this thesis, a non-disclosure agreement was signed, and some data cannot be disclosed.  Background: LORAMAX, the case company for this thesis produces differentiated products on the basis of quality. They are faced with the challenge of making a product that they recently launched, HERO, more competitive in the market. Even though they have chosen a differentiated strategy, the company understands that cost reduction could as well provide them a competitive advantage and is therefore crucial to the survival of the new product.  Research questions:                How can the production cost and lead time be reduced for HERO? How would the choice to either buy pre-assembled modules or manufacture them in-house influence the profit margin of HERO? Purpose: The purpose of this thesis is to use relevant theories and practical tools in order to help the company identify potential opportunities and areas where to reduce assembly costs and lead-times.  Method: The empirical data used to draw conclusions was collected through a mixed research method (both qualitative and quantitative) carried out on site at LORAMAX with the help of the purchasing and production manager, through interviews, questionnaires and observations. This thesis is written from a positivistic perspective with a deductive approach.  Conclusions: Value Stream Mapping (VSM) and Total Cost of Ownership (TCO) are effective tools for cost and lead time reduction and can be used to support a make-or-buy decision. In this thesis, we arrive at the conclusion that LORAMAX will improve its profit margins on HERO if it buys already assembled modules.

Lean production är en väl etablerad produktionsteknik världen över. Inom Lean production finns det flertalet verktyg, ett av dessa är kartläggningsverktyget Value Stream Mapping (VSM). Med VSM kartläggnings information- och materialflöden inom den egna verksamheten, samt så identifieras icke-värdeskapande aktiviteter (slöseri) för att sedan skapa förbättringsförslag. VSM är ett bevisat effektivt verktyg att använda för att skapa effektiva flöden inom många typer av verksamheter såsom: fordonsindustrin, hotellverksamhet, stålindustri, energiindustri. Dock menar författare att VSM inte kan användas inom företag som har en MTO strategi och som karaktäriseras av produkter som tillverkas i låga volymer och höga variationer. I dagens samhälle ökar ständigt efterfrågan på kundanpassade produkter, vilket i sig leder till att fler MTO företag bildas för att kunna möta kundernas krav. Dessa företag har dock samma krav på sig som andra företag, det vill säga att reducera produktionskostnader, korta ner ledtider och öka kvaliteten för att kunna skapa en konkurrenskraft på marknaden. Således skapades problemformuleringen för denna studie: ”Hur kan ett företag som har en Make-To-Order strategi och som karaktäriseras av en produktion med hög grad av variation samt låg volym, använda Value Stream Mapping för att kartlägga värdeflöden och på så vis skapa möjligheter för att effektivisera verksamheten?” För att besvara problemformuleringen genomfördes studien på Bosch Rexroth Mellansel som är ett företag inom ovan nämnda kontext. Företaget erbjuder bland annat kundanpassade lösningar, företaget har en MTO strategi och tillverkningen av de kundanpassade produkterna sker av hög grad av variation samt låg volym. Arbetet utgick sedan från befintliga teorier om Lean production och VSM samt utvecklade verktyg av VSM för att sedan testa och anpassa dessa på den aktuella kontexten. Kartläggningen genomfördes med hjälp av att observera och samtala med arbetare i flödet samt genom att utforma blanketter som fick följa med artikeln där arbetare hade det huvudsakliga ansvaret att fylla i start- och sluttider för processer. I studiens VSM visades material- och informationsflöden samt identifierat slöseri, detta låg sedan som grund för att ge förslag till hur företaget kan effektivisera verksamheten. Studiens huvudsakliga slutsatser innebär att VSM kan anpassas till denna typ av verksamhet genom att: använda flödesfamiljer i kartläggningen i stället för enskilda produkter eller produktgrupper; koppla tidigare försäljning mot respektive flödesfamilj för att därefter skapa en övergripande prioritering och förståelse; kopplitera observationerna med hjälp av att använda blanketter som får ”följa med” produkten, där arbetare få anteckna information om aktuella processtider och väntetider; kommunikation, för att skapa förutsättningar för ett effektivt flöde. Genom tidigare litteratur och observationer skapades slutligen en modell för förslag på framtida arbetsgång för företaget. Slutligen redovisade studien att det är viktigt att anpassa VSM till den aktuella verksamheten samt betydelsen av att involvera arbetare i processen.

Sustainable Value Stream Mapping (Sus-VSM) builds upon traditional VSM to capture additional sustainability aspects of the product flow, such as environmental and societal aspects. This work presents research to expand the utility of Sus-VSM to supply chain networks, develop a general approach towards improving supply chain sustainability, and examine the benefits of implementing simulation and a design of experiments (DOE) style analysis. Metrics are identified to assess economic, environmental, and societal sustainability for supply chain networks and visual symbols are developed for the Supply Chain Sus-VSM (SC Sus-VSM) to allow users to easily identify locations where sustainability can be improved. A discrete event simulation (DES) model is developed to simulate the supply chain, allowing easier creation of future state maps, which are used to identify locations for sustainability improvement. A scoring methodology and DOE-style analysis are developed to collect more information from the supply chain. Results from the case study show that the SC Sus-VSM meets the goals desired, and that the DES model aids the goals of the map. It is also indicated that interventions in the supply chain should first focus on economic improvements, followed by societal and then environmental improvements to achieve the greatest supply chain sustainability.

Syfte: Syftet med examensarbetet är att undersöka möjligheter till effektivisering av fjärrvärmeinstallationer i småhus med hjälp Lean. Detta har gjorts genom att besvara de tre följande frågeställningarna: Hur ser en fjärrvärmeinstallation i småhus ut i dagsläget? Vilka slöserier går att identifiera i processen för fjärrvärmeinstallation i småhus? Hur kan slöserier i processen för fjärrvärmeinstallation i småhus minskas? Metod: För att uppfylla examensarbetets syfte har en fallstudie genomförts på Jönköping Energi som är en leverantör av fjärrvärme. Där har intervjuer och dokumentationsstudier använts som datainsamlingsmetoder. Litteraturstudier har gjorts för att samla in information kring teorier som sedan använts för att utvärdera och analysera empirin. Resultat: Genom studien har slöserier identifierats i processen för fjärrvärmeinstallation i småhus. Det största slöseriet som identifierats är väntan som uppstår mellan delprocesserna, vilken uppgår till 20 % av den totala ledtiden för installationen. Genom att införa ett informationssystem som täcker glappet mellan entreprenörerna och fallstudieföretaget, förändrad tidsplanering samt arbete med parallella processer anses denna väntan kunna minskas. Implikationer: Denna studie visar att med hjälp av Lean kan processen för fjärrvärmeinstallation i småhus effektiviseras och att ledtiden för processen kan förkortas genom eliminering av slöserier. Studien visar också att genom att använda periodlös planering kan ledtiden förkortas ytterligare då tidsplaneringen anpassas efter verksamheten. Begränsningar: Studien som genomförts baseras på empiri som samlats in på ett fallstudieföretag, genom att öka antalet fallstudier samt genomföra dessa på fler en ett företag ökar generaliserbarheten i resultaten. / Purpose: The purpose of this study is to investigate the possibilities for improving the efficiency of district heating installations in houses by using Lean. This is done by answering the following three questions: How is a district heating installation implemented? What types of wastes can be identified in the process of district heating installations in houses? How can wastes in the process of district heating installations in houses be reduced? Method: In order to fulfill the purpose of the study a case study has been conducted at Jönköping Energi, a supplier of district heating. Interviews and documentation studies have been used as data collection methods. Literature studies have been made to collect information on theories that were used to evaluate and analyze empirical data. Results: Wastes in the process of district heating in houses has been identified in the study. The biggest identified waste is the wait that occurs between the sub-processes, where wait reach up to 20 % of the total lead time of the installation. By implementing an information system, introducing changes in scheduling and start working in with parallel processes this wait can be reduced. Implications: This study shows that by using Lean the process of district heating installations in houses can be more efficient and that the lead time for the process can be shortened by eliminating wastes. The study also shows that by using bucketless planning, lead time can be shortened further when scheduling adapts to the process. Limitations: The study was carried out based on only one case study. By increasing the number of case studies and by carry those out in more than one company the generalizability of the results will be increased.

As organizações do setor público são normalmente associadas a processos lentos, burocráticos e que geram resultados insuficientes. Em função disso, têm crescido as exigências relativas ao desempenho dos órgãos do setor público. A aplicação dos conceitos Lean é uma alternativa para reduzir as perdas do setor púbico e aumentar a eficiência no uso dos recursos. Nesse contexto, este estudo tem como objetivo analisar e propor melhorias no processo de contratação de obras de uma universidade pública, com foco na eliminação das perdas, através da utilização do Mapeamento do Fluxo de Valor (MFV), bem como identificar barreiras para a aplicação do MFV e das melhorias identificadas por meio dessa ferramenta. A estratégia de pesquisa adotada foi o estudo de caso aplicado ao processo de contratação de uma obra na Universidade Federal de Mato Grosso (UFMT). Com base no MFV, foram propostas melhorias no processo, sinalizando para uma possível redução do lead time de 1.242 dias para 380 dias. Através da aplicação do MFV, também foi possível identificar barreiras para implantação dos princípios lean, como a falta de padronização dos procedimentos, falta de visão sistêmica do fluxo do processo por parte dos gestores, deficiência na capacitação dos servidores, falta de foco no cliente final e dificuldades de adaptar conceitos a práticas. Pelos resultados obtidos, é possível afirmar que os procedimentos administrativos, no contexto de obras em uma universidade pública, podem ser melhorados com a aplicação do MFV. / Public organizations are usually associated to slow bureaucratic processes with little result. Therefore, there is a growing demand for higher performances in the public sector. Using lean concepts is an alternative to reduce the losses in the public sector and enhance the efficiency of recourse use. The research herein presented is aimed at analyzing and proposing improvements in the bidding process for construction works within a public university, focusing on loss elimination, through the use of Value Stream Mapping (VSM). Besides, we intend to identify obstacles to using VSM and the benefits that come from the use of such tool. We have done a case study about the bidding process for construction works within the Federal University of Mato Grosso (UFMT). Based on VSM, we suggested improvements to the process through a possible reduction of the lead time from 1242 days to 380 days. By using VSM, it was also possible to identify obstacles to the lean principles, such as the lack of procedural standardization, the fact that managers do not have a systemic view of the process stream, employees’ need for training, lack of focus on the end client and difficulties to adapt concepts into practices. From the results, we can affirm that administrative procedures in a public university can be improved by using VSM.

As organizações do setor público são normalmente associadas a processos lentos, burocráticos e que geram resultados insuficientes. Em função disso, têm crescido as exigências relativas ao desempenho dos órgãos do setor público. A aplicação dos conceitos Lean é uma alternativa para reduzir as perdas do setor púbico e aumentar a eficiência no uso dos recursos. Nesse contexto, este estudo tem como objetivo analisar e propor melhorias no processo de contratação de obras de uma universidade pública, com foco na eliminação das perdas, através da utilização do Mapeamento do Fluxo de Valor (MFV), bem como identificar barreiras para a aplicação do MFV e das melhorias identificadas por meio dessa ferramenta. A estratégia de pesquisa adotada foi o estudo de caso aplicado ao processo de contratação de uma obra na Universidade Federal de Mato Grosso (UFMT). Com base no MFV, foram propostas melhorias no processo, sinalizando para uma possível redução do lead time de 1.242 dias para 380 dias. Através da aplicação do MFV, também foi possível identificar barreiras para implantação dos princípios lean, como a falta de padronização dos procedimentos, falta de visão sistêmica do fluxo do processo por parte dos gestores, deficiência na capacitação dos servidores, falta de foco no cliente final e dificuldades de adaptar conceitos a práticas. Pelos resultados obtidos, é possível afirmar que os procedimentos administrativos, no contexto de obras em uma universidade pública, podem ser melhorados com a aplicação do MFV. / Public organizations are usually associated to slow bureaucratic processes with little result. Therefore, there is a growing demand for higher performances in the public sector. Using lean concepts is an alternative to reduce the losses in the public sector and enhance the efficiency of recourse use. The research herein presented is aimed at analyzing and proposing improvements in the bidding process for construction works within a public university, focusing on loss elimination, through the use of Value Stream Mapping (VSM). Besides, we intend to identify obstacles to using VSM and the benefits that come from the use of such tool. We have done a case study about the bidding process for construction works within the Federal University of Mato Grosso (UFMT). Based on VSM, we suggested improvements to the process through a possible reduction of the lead time from 1242 days to 380 days. By using VSM, it was also possible to identify obstacles to the lean principles, such as the lack of procedural standardization, the fact that managers do not have a systemic view of the process stream, employees’ need for training, lack of focus on the end client and difficulties to adapt concepts into practices. From the results, we can affirm that administrative procedures in a public university can be improved by using VSM.

A crescente competição mundial exige que as empresas sejam cada vez mais ágeis e enxutas. Por isso, a idéia de otimização de processos tem estado nas discussões e nas estratégias traçadas para a manutenção da competitividade destas empresas e para que as indústrias tenham seus diferenciais de mercado. A produção enxuta, originária da indústria japonesa, é uma filosofia que vem de encontro a atender esta necessidade. Este trabalho apresenta um modelo que visa auxiliar o desenvolvimento de produção enxuta em empresas, em especial na indústria aeroespacial onde as aplicações foram estudadas, apresentando as vantagens do uso compartilhado de duas ferramentas de auxílio na implementação de um processo produtivo enxuto: o Visioneering e o mapeamento de fluxo de valor, vistos sob a ótica da metodologia Transmeth. Para tal, partiu-se de uma introdução teórica dos principais conceitos em torno destes assuntos, passando pelo relato de algumas utilizações destas ferramentas isoladamente na Embraer e chegando à elaboração do modelo de aplicação propriamente dito. / The increasing worldwide competition demands companies to become lean and agile. Therefore, the idea of process organization has been present in most discussions and strategies traced for the competitive maintenance of these companies and the industries to promote market differentiation for industries. And lean manufacturing, original from Japanese industry, is a philosophy that intends to attend this worldwide need. This work presents a model that it aims at to assist the development of lean production in companies, specially in the aerospace industry where the applications had been studied, presenting the advantages of the shared use of two tools of aid in the implementation of a lean productive process: the Visioneering and the value stream mapping, visas under the optics of the Transmeth methodology. For such, it was broken of a theoretical introduction of the main concepts in lathe of these subjects, passing for the story of some uses of these tools separately in the Embraer and arriving in the elaboration of the model of application properly said.

\"Houve época em que as empresas podiam ser organizações focadas nos próprios processos produtivos e comerciais, pressionando o mercado a se adaptar a suas necessidades ou características, de acordo com o modelo de negócios por elas praticado. Na medida em que a sociedade e o mercado se alteraram em profundidade e complexidade, exigindo ao mesmo tempo melhores produtos, mais resultados e ganhos crescentes, as empresas passaram a sentir a necessidade de se envolver num processo contínuo de melhoria\", (PINEDO, 2003). Devido ao processo de globalização produtiva os concorrentes passaram a pressionar muito mais duramente, pelo fato espantoso de que o espaço de mercado passou a ser o mundo inteiro. Defeitos e atrasos na entrega dos produtos são mazelas não mais aceitas pelos consumidores. A crescente exigência destes por produtos customizados e entregas rápidas tem provocado um litígio entre as empresas e o tradicional sistema de produção em massa, que muitas vezes não consegue atingir as expectativas dos clientes. Para se adaptarem a esse ambiente competitivo, as empresas de manufatura, seguindo os passos da indústria automobilística, estão cada vez mais utilizando os conceitos e técnicas da Produção Enxuta, ou seja, produzindo em resposta a demandas específicas, somente quando necessário, controlando a qualidade do produto e do prazo de entrega, e ao mínimo custo. Nesse sentido, o objetivo desse trabalho é propor um método de implantação de sistema Kanban que possa auxiliar as organizações a utilizarem esta ferramenta da Produção Enxuta, retirando dessa os maiores benefícios possíveis, como redução do inventário, melhoria do sistema de gerenciamento, redução de atrasos em entregas, entre outros. Esse método deverá servir como base de orientação para os envolvidos num processo de implantação de Kanban. / \"There were time where the companies could be organizations directed in the proper productive and commercial processes, pressuring the market to adapt its necessities or characteristics, in accordance with the model business-oriented for them practised. In the measure where the society and the market have modified in depth and complexity, demanding at the same time better products, more increasing results and profits, the companies had started to feel the necessity of involving in a continuous process of improvement\" (PINEDO, 2003). In consequence of the process of globalization\'s productive the competitorshad started to pressure much more hardly, for the amazing fact that the market space started to be the entire world. Defects and delays in the delivery of the products are problems not more accepted for the consumers. The increasing requirement of these for specific products and special deliveries has provoked a litigation between the companies and the traditional system of mass production, that many times do not obtain to reach the expectations of the customers. To be detached to this competitive environment, the companies of manufacture, following the steps of the automobile industry, are each time more using the concepts and techniques of the Lean Production, or either, producing in reply the specific demands, only when necessary, controlling the stated period and product quality of delivery, and minimum cost. In this direction, the objective of this work isto consider a method of system implantation Kanban that it can assist the organizations to use this tool of the Lean Production, removing that the biggest possible benefits, as reduction of inventory, improvement of the management system, reduction of delays in deliveries, among others. This method will have to serve as base of orientation for the involved ones in a process of Kanban\'s implantation.