A dissertação aborda o estudo sobre as principais características observadas sob a perspectiva da gestão de custos em indústrias de manufatura discreta, em especial considerando uma possível integração dos Sistemas Enterprise Resource Planning (ERP) com os chamados Manufacturing Execution Systems (MES). Este estudo procurar elucidar acerca das iniciativas orientadas à redução de custos, especialmente aquelas aplicas em manufaturas do tipo discreta. Por meio do método de estudo múltiplo de casos foram coletados dados a respeito da implementação do MES e seus impactos sobre a redução de custos em três organizações, para que fossem debatidas as visões de diversos gestores, verificando se as hipóteses levantadas ao longo do projeto são confirmadas. Por fim, os resultados observados foram analisados e discutidos, e as conclusões apontam que o uso do sistema MES pode contribuir ou possui potencial para reduzir os custos e também para aumentar o controle da gestão. No entanto, foi possível observar também que a implantação de sistemas deve ser acompanhada de mudanças de processos e de cultura, que propiciem de fato a redução de custos nas empresas. Foram propostas novas possibilidades para que seja possível a continuidade de outros estudos neste sentido, de forma que as organizações possam explorar novas possibilidades, aperfeiçoando os sistemas ou desenvolvendo mudanças em seus processos. / The dissertation describes the study on major features achieved from the perspective of cost management within discrete manufacturing industries, especially considering a possible integration between Enterprise Resource Planning (ERP) systems with so-called Manufacturing Execution Systems (MES). This study seeks to enlighten a few initiatives on the subject concerned to cost reduction management belonged to the company, especially those applied among manufacturers whose type is settled as discrete. By using the multiple case study method, several data regarding MES implementation and also its impacts on cost decrease were gathered within three enterprises, and therefore used for debating some standpoints from several managers and verifying whether the assumptions made throughout the article are confirmed. Finally, the results obtained along this study were analyzed and discussed, and such findings lead to idea that MES system use can concur or has the potential to decrease costs and also enhance the management control. However, it was also possible to behold that systems implementation should be followed by a culture and processes changes as well, that surely provide cost cutting among companies. It was proposed some other improvement possibilities in order to make possible the development of new efforts in this regard, in a way that enterprises are able to explore new paths, enhancing the systems or even developing changes in their processes.

A dissertação aborda o estudo sobre as principais características observadas sob a perspectiva da gestão de custos em indústrias de manufatura discreta, em especial considerando uma possível integração dos Sistemas Enterprise Resource Planning (ERP) com os chamados Manufacturing Execution Systems (MES). Este estudo procurar elucidar acerca das iniciativas orientadas à redução de custos, especialmente aquelas aplicas em manufaturas do tipo discreta. Por meio do método de estudo múltiplo de casos foram coletados dados a respeito da implementação do MES e seus impactos sobre a redução de custos em três organizações, para que fossem debatidas as visões de diversos gestores, verificando se as hipóteses levantadas ao longo do projeto são confirmadas. Por fim, os resultados observados foram analisados e discutidos, e as conclusões apontam que o uso do sistema MES pode contribuir ou possui potencial para reduzir os custos e também para aumentar o controle da gestão. No entanto, foi possível observar também que a implantação de sistemas deve ser acompanhada de mudanças de processos e de cultura, que propiciem de fato a redução de custos nas empresas. Foram propostas novas possibilidades para que seja possível a continuidade de outros estudos neste sentido, de forma que as organizações possam explorar novas possibilidades, aperfeiçoando os sistemas ou desenvolvendo mudanças em seus processos. / The dissertation describes the study on major features achieved from the perspective of cost management within discrete manufacturing industries, especially considering a possible integration between Enterprise Resource Planning (ERP) systems with so-called Manufacturing Execution Systems (MES). This study seeks to enlighten a few initiatives on the subject concerned to cost reduction management belonged to the company, especially those applied among manufacturers whose type is settled as discrete. By using the multiple case study method, several data regarding MES implementation and also its impacts on cost decrease were gathered within three enterprises, and therefore used for debating some standpoints from several managers and verifying whether the assumptions made throughout the article are confirmed. Finally, the results obtained along this study were analyzed and discussed, and such findings lead to idea that MES system use can concur or has the potential to decrease costs and also enhance the management control. However, it was also possible to behold that systems implementation should be followed by a culture and processes changes as well, that surely provide cost cutting among companies. It was proposed some other improvement possibilities in order to make possible the development of new efforts in this regard, in a way that enterprises are able to explore new paths, enhancing the systems or even developing changes in their processes.

The purpose of this study is to identify the challenges and opportunities for digitalization within the food industry, and give suggestions on how to co-create value through digitalization.  This qualitative study is based on data collected from scientific articles, reports and books about digitalization and value co-creation in the food industry. The primary data collection was carried out by twelve semi-structured interviews and a complementary food industry study with eleven respondents. The collected data was handled in thematic analysis and inspired by coding.  The study’s main conclusion was the discovering of a new value co- creation mechanism defined as relationship and learning.

Presented PhD thesis aims at development of new methodologies and approaches to reduce lead times in production systems. Therefore the thesis examines in detail the design of new, more comprehensive approaches to shortening lead times. The dissertation describes the methodology of using these approaches in production systems, it is suggested their inclusion in the control structure of production and adequate managerial support for the successful application of these new approaches in the industry is developed. The first part summarizes current knowledge in the field of reducing lead times. The various methods that can be used for reducing lead times are defined and described, from which is selected discrete simulation of manufacturing systems as a suitable method for the purposes of issue development. The next part of this work is therefore devoted to simulation approach to reducing lead times and the factors that affect them, such as processing time, size of the batch, queue lengths, etc. In this part is also discussed the use of information technologies (programming languages, libraries, and software tools) that enable efficient creation of simulation models. The second part is focused on industrial applications implemented to reduce production lead times. Specific simulation analysis deal with, for example, reduction of the lead time for manufacture of surgical instruments, screws, slats, but also transport systems, optimization of production orders input to the production system, the issue of supply, etc. The second part also describes a practical approach to data transfer to / from the simulation model, simulation software connection to the ERP database of enterprise and energy intensity of production. The conclusion summarizes the findings that were detected on the issue of reducing lead times, and within the chosen methodology, simulation of manufacturing processes indicates possible further progress in the research and practical applications.

This thesis presents the work of a master degree project in mechatronics by two students from The Royal Institute of Technology. The project was carried out during spring 2017 in collaboration with Bosch Rexroth Mellansel as part of their desire to improve their operations. It is also in line with the Bosch Groups ambition to lead the development within Industry 4.0. The aim was to investigate the information need on a discrete manufacturing process and how radio-frequency identification (RFID) can be used to cover that need. The background research was made with qualitative methods using a literature review on relevant areas and a case study of Bosch Rexroth Mellansel. A discrete event simulation was created to confirm the possibilities of an RFID tracking system. It acted as a target for what the developed demonstrator should fulfil and was realised through a system of four wireless nodes connected in a mesh network. The plant in Mellansel partially implemented a Bosch standardised RFID system in parallel with the development of the demonstrator, which enabled a comparison of the two systems. The results show that from a tag event, which gives information on what, where and when, it is possible to, in real time, analyse and visualise valuable key performance indicators for a production process. It is also possible to use the data to automate transactions in an enterprise resource system which removes non-value adding activities from an operator while also ensuring consistency in the reporting procedure. The results indicate that benefits can be achieved. However, this requires further quantitative analysis before it can be fully confirmed and be used to push the development of Industry 4.0 forward. / Denna rapport presenterar ett examensarbete inom mekatronik av två studenter från Kungliga Tekniska Högskolan. Projektet genomfördes under våren 2017 i samarbete med Bosch Rexroth Mellansel som en del av deras strävan att förbättra sin verksamhet. Det ligger också i linje med Bosch koncernens ambition att leda utvecklingen inom Industri 4.0. Syftet var att undersöka informationsbehovet hos en diskret tillverkningsprocess och hur radio-frequency identification (RFID) kan användas för att täcka detta behov. Bakgrundsstudien gjordes med kvalitativa metoder som litteraturstudie inom relevanta områden och en fallstudie av en produktionsprocess inom Bosch Rexroth Mellansel. En simulering av produktionsprocessen skapades för att bekräfta möjligheterna av att använda ett RFID system för spårning av objekt. Den fungerade som ett mål för vad den utvecklade demonstratorn skulle uppfylla och realiserades genom en prototyp bestående av fyra trådlösa noder samlade i ett mesh nätverk. Parallellt med utvecklingen av demonstratorn gemomförde fabriken i Mellansel en del-implementering av en Bosch-standardiserad RFID lösning, vilket möjliggjorde en jämförelse av de två systemen. Resultaten visar att det från en avläsning av en tag, som ger information om vad, var och när, så är möjligt att i realtid analysera och visualisera värdefulla nyckeltal för en produktionsprocess. Det är också möjligt att använda data för att automatisera transaktioner i ett affärssystem som tar bort icke värdeskapande aktiviteter för operatören och samtidigt säkerställer en standardiserad rapporteringsprocess. Resultaten visar att fördelar kan uppnås men kräver ytterligare kvantitativ analys innan de kan bekräftas till fullo och användas för att driva utvecklingen av Industri 4.0 framåt.

In following a lean transformation specifically for discrete manufacturing, how and why will the organisational structure be affected? How will the employees deal with this profound change? Lean theory and literature propose that organisations should be restructured according to the value stream of the organisation; what does this imply and how can it be accomplished? The purpose of this study was to determine, from a new perspective, guidelines and theory that could indicate how and why organisational structures and behaviours might change with lean transformation. Two discrete manufacturing organisations in South Africa were purposively sampled for this purpose. A conceptual framework was used at the outset that indicated constructs for the independent lean variables and the dependent organisational structure and behaviour variables. Using a mixed methodology case study and quantitative multiple linear regression approach, hypotheses and propositions for the research were developed. Multiple linear regression was used to test the hypotheses, and case study methodology was applied to analyse and test the qualitative data. Findings confirmed the hypotheses and propositions that a flat structure consisting of business units that support manufacturing cells achieves effective lean transformations in discrete manufacturing organisations. The research revealed the components of an effective lean structure as open constructive leadership, an effective lean champions unit and business units that support linked manufacturing cells. These are led by cell leaders who cultivate supportive behaviours through cross-functional teamwork and through self-directed work teams who run manufacturing cells or flow support functions. / Business Management / D.B.L.

Syftet med detta examensarbete har varit att ta fram vilka leanprinciper och leanverktyg som passar en processindustri med målet att minska ledtiden. För att kunna genomföra studien har en jämförelse mellan teori och verklighet gjorts där hjälp tagits av Lesjöfors industrifjädrar AB. Utmärkande aspekter för företagets produktion är långa led- och omställningstider, produktion i batcher med stora partistorkekar samt tryckande tillverkning. Litteraturstudien omfattar fem principer och fem verktyg. För att identifiera nuläget har en värdeflödeskartläggning genomförts samt intervjuer med anställda på företaget. När teori kopplas med empiri har lämpliga principer och verktyg utifrån de studerade 10 valts ut. De principer som har identifierats som lämpliga för en processindustri är standardiserat arbetssätt, ständiga förbättringar, utjämnad produktion. De verkyg som utefter principerna identifierats som lämpliga är SMED, 5S samt värdeflödeskartläggning. Dessa har sedan används i en sammanfattning i form av ett TPS-hus, unikt för produktionen på Lesjöfors industrifjädrar AB. / The aim of this bachelor thesis has been to identify which lean principles and lean tools that would suit a process industry with the goal of reducing lead times. In order to complete the study, a comparison between theory and reality has been made where assistance has been provided by Lesjöfors industrifjädrar AB. Key aspects of the company's production include long lead times and set up times, production in batches with large lots and push production. The literature study comprises five principles and five tools. To identify the current situation, a value stream mapping has been conducted and interviews with employees at the company. When theory is linked with empirical studies, suitable principles and tools based on the selected 10 have been chosen. These have then been used in a summary in the form of a TPS-house, unique to the production at Lesjöfors industrifjädrar AB.

In following a lean transformation specifically for discrete manufacturing, how and why will the organisational structure be affected? How will the employees deal with this profound change? Lean theory and literature propose that organisations should be restructured according to the value stream of the organisation; what does this imply and how can it be accomplished? The purpose of this study was to determine, from a new perspective, guidelines and theory that could indicate how and why organisational structures and behaviours might change with lean transformation. Two discrete manufacturing organisations in South Africa were purposively sampled for this purpose. A conceptual framework was used at the outset that indicated constructs for the independent lean variables and the dependent organisational structure and behaviour variables. Using a mixed methodology case study and quantitative multiple linear regression approach, hypotheses and propositions for the research were developed. Multiple linear regression was used to test the hypotheses, and case study methodology was applied to analyse and test the qualitative data. Findings confirmed the hypotheses and propositions that a flat structure consisting of business units that support manufacturing cells achieves effective lean transformations in discrete manufacturing organisations. The research revealed the components of an effective lean structure as open constructive leadership, an effective lean champions unit and business units that support linked manufacturing cells. These are led by cell leaders who cultivate supportive behaviours through cross-functional teamwork and through self-directed work teams who run manufacturing cells or flow support functions. / Business Management / D.B.L.

The purpose of this dissertation is to propose a framework for sales and operations planning (S&OP), which is based on a modularized view of supply chains. The framework should support both process industries and discrete manufacturing industries in their quest for performance. S&OP has been highlighted in this framework due to its essential role in integrating different functions within a company and integrating a company with its supply chain partners (referred to as horizontal integration), and linking different planning levels in a company (referred to as vertical integration). As an integrator, S&ÖP influences companies’ performance. Originally, S&OP was developed as a generic process but still in line with the requirements of discrete manufacturing industries. The specific requirements of process industries have not been emphasized in this process to the same extent. In order to suggest a modularized S&OP framework for both process industries and  discrete manufacturing  industries, a systematic literature review is performed to understand the specific characteristics of S&OP in process industries. As a result, the importance of continuity/discontinuity of materials and its influence on the required production processes are highlighted. This indicates that the production process in process industries is actually a hybrid of continuous production and discrete production, whereas the discrete manufacturing industries often only deploy discrete production. Continuous production has specific characteristics that would be beneficial to include in the S&OP process; nonetheless, this is in contrast to the view in the literature that considers S&OP a generic process. Generic here means that S&OP is independent of the context in terms of, for example, the industry in which it is implemented. This issue is investigated in this dissertation by identifying the requirements, which can be considered in the S&OP of process industries as add-ons to the generic S&OP. In addition to this, two other concepts addressing the properties of the production process are identified as important in planning and control, including S&OP. One addresses the level of repetitivity of the production process in response to the market demand, and the other concerns the trigger of the production flow. The three concepts are related to three different types of decoupling points and are the basis for a typology developed herein that provides a modularized view of supply chains. The application of the typology to S&OP leads to a modularized S&OP framework applicable to both process industries and discrete manufacturing industries. The modularized view of supply chains has been long emphasized as an effective and efficient way to support companies’ performance and their competitive position. The typology and the S&OP framework are developed through conceptual research methods. To study how the modularized S&ÖP framework is related to companies’ performance measures, different performance measures (including sustainable performance measures) at the S&OP level are extracted from the literature. The performance measures are then classified according to the typology, and linked to strategic performance attributes. Aligning performance measures at S&OP levels and strategic performance attributes would help in enhancing companies’ performance. Sustainable performance measures are included in this classification to provide additional support for companies’ performance. Finally, this approach in classification of  performance measures is studied in four case companies, and the empirical performance measures are linked to the companies’ strategic performance attributes and competitive strategies. The results of this empirical study have, to some extent, verified the results from the classification of performance measures based on the literature. This dissertation contributes to the development of knowledge in S&OP. First, it identifies three key concepts in planning and control of manufacturing companies. Second, it investigates how S&OP should be tailored to the specific characteristics of companies and their supply chains. The modularized S&OP framework developed in this dissertation is based on the three identified concepts. This framework provides a foundation for fulfilling the supply chains needs by suggesting decision-making processes, planning techniques, and performance measures for different modules. More specifically, this work investigates how S&OP should be designed and implemented in process industries, which has not been extensively studied before. Third, this dissertation shows how S&OP level performance measures can be selected in line with the specific characteristics of supply chains. Finally, by integrating the sustainable performance measures in the S&OP process, this dissertation expands the scope of S&OP and its potential in supporting companies’ performance.