Stora Enso’s (SE) division consumer board has launched a World Class Manufacturing (WCM) investment throughout all their production units in the world. An internal education program started a project to reduce short stops in the packaging line at the mill in Skoghall, Sweden. This thesis seeks to evaluate a continuous improvement (CI) project and distinguish some of the key factors for SE to succeed with another implementation in the future. The project will involve operators in the CI work and together with these shift teams made a structured way of working with short stops. The data collection methods have both been qualitative and quantitate such observations, conversations, meetings and stop data from the internal stop and interruption program. This thesis indicates that SE hasstarted their journey towards WCM but many obstacles are in their way. A change of focus and involvement will be needed to succeed in the future.

Examensarbetet utfördes på monteringsavdelningen på GKN Driveline AB i Köping där slut-och vinkelväxlar monteras och sedan förses till globala kunder inom personbilsindustrin. Den totala takttiden för den monteringsbana som detta projekt innefattade är 64 sekunder, men i dagsläget blir den totala takttiden ofta högre. Problemet är att det inte går att se om montören taktar rätt eller inte på respektive monteringsstation, vilket resulterar i att det inte går att identifiera var någonstans på banan tidsförlusten sker och var rotorsaken ligger vid en för lång takttid, då det inte finns någon indikator på detta. Syftet med detta projekt var att ta fram en lösning på en visualisering som gör att montören kan se takttiden på respektive station. För-och nackdelar med en visualisering analyserades, utvärderades och presenterades och även en övergripande kostnadskalkyl togs fram. Den skriftliga rapporten fungerar som ett underlag för en eventuell implementering. Till grund för examensarbetet stod litteraturstudier inom områdena Lean och stress, extern benchmarking för insamling av information och inspiration samt intervjuer med anställda på GKN Driveline för att lyfta fram åsikter och tankar om en eventuell visualiserings påverkan på människan. Utöver informationsinsamlingen ovan genomfördes en egen metod för framtagning av den slutliga lösningen. Lösningen som togs fram var en tilläggsprodukt till företagets redan befintliga industrisystem. Produkten visualiserar takttiden för montören samt registrerar och lagrar data, vilket medför flera olika fördelar. Diskussion om hur visualiseringen ska bli så effektiv som möjligt tillsammans med slutliga rekommendationer har lagts fram och om implementeringen genomförs och medför förbättrat produktionsresultat kan visualiseringen med fördel appliceras på samtliga monteringsbanor på företaget. / The thesis was performed on the department of assembling at GKN Driveline AB in Koping, where final- and bevel gear is assembled and then provided to global customers in the car industry. The total rate for the assembly line which this project included is 64 seconds, but in the current situation the total rate is often higher. The problem is that it’s not possible to see if the assembler tact right or not on each assembly station, resulting in that it’s not possible to identify where on the line the time loss occurs and where the root cause lies in a rate that’s too high, when there’s no indicator on that. The aim of this project was to produce a solution that makes it possible for the assembler to see the rate on each station. Advantages and disadvantages with a visualization was analyzed, evaluated and presented, and an overall cost estimate was also produced. The written report works as a foundation for a possible future implementation. The basis of the thesis were literature studies in the areas of Lean production and stress, external benchmarking to collect information and inspiration, and also interviews with the employees at GKN Driveline to highlight the views and thoughts on a possible effect of a visualization on humans. In addition to the collecting of the different information above a proprietary method for the production of the final solution was implemented. The final solution that was produced was an enhancement to the company’s already existing industrial system. The product visualizes the rate for the assembler and records and stores data which entails several advantages. A discussion about how the visualization will be as efficient as possible together with final recommendations have been presented and if the implementation is carried out and improves the production result the visualization can be usefully applied to all the company’s assembly lines.

Object of this thesis is to give elaborated view of ways and methods for officiating of the efficiency of quality management systems. This thesis is describing and evaluating the current state of quality management systems in chosen firm. In this firm are further applied chosen indicators of the efficiency of quality management. On the basis of quantification of quality management systems efficiency are exposed main problems in quality management in selected firm. This thesis contains proposed correctional remedies for chosen problems elimination. On the basis of repeated measures is further efficiency assessed for realized remedies and is discovered current efficiency of quality management systems in chosen firm.

The aim of this work is to analyze the effectiveness of processes and administration in a particular project in the company of engineering sector and to suggest possible measures to help the company become lean. The theoretical part presents the issue of lean management, describes its history and basic elements, corporate culture and also the philosophy of the Toyota Production System. This thesis also describes in detail particular methodological tools, including Kaizen philosophy, furthermore there is mentioned the theory of lean office. The practical part begins with introduction of the company and with the analysis of the current situation of innovation activities in the company. In the next chapter, there is described in detail the project in production shop, waste analysis and overall project analysis is made. The following is a summary of outputs, evaluation of the state and proposal of measures for the future periods.

This master’s thesis is focused on implementation of lean manufacturing methods. The beginning of the study deals with history and description of theoretical tools. Next part describes company ABB and gas-insulated high-voltage substations. Followed by process flow analysis before and after moving the company. There is described assembly and product portfolio in this thesis. Last chapters deal with the application of lean manufacturing methods and economy evaluation.

Las empresas comercializadoras mayoristas se vienen enfrentando a nuevos retos en cuanto al nivel de servicio, el cual es un factor importante y el que determina el nivel de ventas y la rentabilidad de las empresas. Es así que, actualmente, las empresas se rigen a entregar los pedidos a sus respectivos clientes a tiempo, en buen estado y completos. Este documento se centra en la importancia de la gestión de almacenes para las distribuidoras de consumo masivo, ya que son los almacenes los que determinan los costos de operación y productividad de estas. Es así que algunas técnicas innovadoras como el lean warehouse y herramientas de asignación, mejoran las condiciones de trabajo con el objetivo de reducir tiempos muertos y distancias. Se llevó a cabo un piloto de implementación de las herramientas mencionadas en el almacén de una distribuidora mayorista. Como resultado de la investigación se logró la reducción de la distancia recorrida en almacén en un 22%, la reducción de tiempos en el proceso de picking, logrando el tiempo óptimo de entregas y generando un incremento de las ventas efectuadas de 215,720.22 soles. Estos resultados demuestran ser determinantes en el rendimiento de la cadena de suministro (inventario, costo, retraso y riesgo), ya que la clave del éxito para esta industria es satisfacer las necesidades de los clientes en el menor tiempo posible. La presente investigación se justifica en la necesidad de incrementar la productividad dentro de una empresa distribuidora de productos de consumo masivo, mejorando los procesos claves de la misma. Esto con el objetivo de contribuir al crecimiento de la rentabilidad de la empresa. / The wholesale trading companies are facing new challenges in terms of the level of service, which is an important factor which determines the level of sales and profitability of companies. Thus, currently, companies are aimed to deliver orders to their respective customers on time, in good condition and complete. This file focuses on the importance of warehouse management for mass consumption distributors, since it’s the warehouses that determine the operation and productivity costs of these. Thus, some innovative techniques such as the lean warehouse and allocation tools improve working conditions with the aim of reducing downtime and distances. A pilot programme of implementation of the tools mentioned in the warehouse of a wholesale distributor was carried out. As a result of the research, the distance traveled in the warehouse was reduced by 22%, the reduction of times in the picking process, achieving the optimal delivery time and generating an increase in the sales made of 215,720.22 soles. These results prove to be decisive in the performance of the supply chain (inventory, cost, delay and risk), since the key to success for this industry is to satisfy the needs of customers in the shortest possible time. This research is justified in the need to increase productivity within a company that distributes consumption products, improving its key processes. This with the objective of contributing to the growth of the profitability of the company. / Tesis

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / At present, companies in the Peruvian plastic sector have an average capacity utilization indicator of 71.45%. However, in Peru many SMEs are with 50% well below this indicator. After a study performed in a representative company of the Peruvian plastic sector, the causes of low efficiency in resource utilization were determined through a problems tree and a Pareto analysis. These causes are failures, reprocesses and Setup times in the extrusion machines, taking around 1008 h a year to solve these problems. This article proposes a model to improve efficiency, integrating Lean Manufacturing tools such as 5s, SMED, and autonomous maintenance. The first one was used as a support tool, while SMED was used to reduce the configuration time and autonomous maintenance to reduce the failures number and the reprocesses number. The model was validated through a case study, obtaining as results the reduction of the setup time by 50%, breakdowns by 50% and reprocesses by 60%.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The manufacturing specifications used by small leather and footwear businesses are neither up to date nor based on innovative production and new technologies. Consequently, their production times are higher, rendering them unable to sufficiently compete against other developed countries. Thus, this study seeks an innovative way to reduce times that do not add value to the product, such as reducing travel distances between stations, and proposes improving procedures for a better monitoring of the resources required. As a whole, this proposal focuses on designing a model to minimize the displacement of different processes. This practice is currently being implemented in the manufacturing sector, but not in the footwear sector. The proposal provides broad results, saving around 33% in transfer times and 85% in distance traveled in footwear production.

In recent decades, the demand for a wide variety of products, lead to the requirement of having a reduced cost of manufacturing, shorter cycle times and perfect quality; forcing companies to implement different engineering techniques to have the best manufacturing system. With which it seeks to efficiently control the process, provide an optimal area of work, establish performance standards with respect to the operations that the company performs, thus generating better results in the organization to achieve higher levels of user satisfaction. In the case of the study, the main line of production in the company was analyzed, detecting that representative costs originated from reprocessing and downtime. The result of greater impact obtained was the reduction of the problems in one (60%) and (15%) respectively. In this way, it is expected that companies in the paint industry or products related to the sector can use the results obtained as a reference in their process of continuous improvement, improving the management and performance of the organization and customer satisfaction.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The wholesale trading companies are facing new challenges in terms of the level of service, which is an important factor which determines the level of sales and profitability of companies. Thus, currently, companies are aimed to deliver orders to their respective customers on time, in good condition and complete. This file focuses on the importance of warehouse management for mass consumption distributors, since it's the warehouses that determine the operation and productivity costs of these. Thus, some innovative techniques such as the lean warehouse and allocation tools improve working conditions with the aim of reducing downtime and distances. A pilot programme of implementation of the tools mentioned in the warehouse of a wholesale distributor was carried out. As a result of the research, the distance traveled in the warehouse was reduced by 22%, the reduction of times in the picking process, achieving the optimal delivery time and generating an increase in the sales made of 215,720.22 soles. These results prove to be decisive in the performance of the supply chain (inventory, cost, delay and risk), since the key to success for this industry is to satisfy the needs of customers in the shortest possible time.