This research presents results from a multi-site field study of 51 Kaizen event teams in six manufacturing organizations. Although Kaizen events have been growing in popularity since the mid 1990s, to date, there has been no systematic empirical research on the determinants of Kaizen event effectiveness. To address this need, a theory-driven model of event effectiveness is developed, drawn from extant Kaizen event practitioner articles and related literature on projects and teams. This model relates Kaizen event outcomes to hypothesized key input factors and hypothesized key process factors. In addition, process factors are hypothesized to partially mediate the relationship between input factors and outcomes. Following sociotechnical systems (STS) theory, both technical and social (human resource) aspects of Kaizen event performance are measured. Relationships between outcomes, process factors and input factors are analyzed through regression, using generalized estimating equations (GEE) to account for potential correlation in residuals within organizations. The research found a significant positive correlation between the two social system outcomes (attitude toward Kaizen events and employee gains in problem-solving knowledge, skills and attitudes). In addition, the research found significant positive correlations between the social system outcomes and one technical system outcome (team member perceptions of the impact of the Kaizen event on the target work area). However, none of the three technical system outcomes (employee perceptions of event impact, facilitator ratings of event success and actual percentage of team goals achieved) were significantly correlated. In addition, the research found that each outcome variable had a unique set of input and process predictors. However, management support and goal difficulty were a common predictors of three out of five outcomes. Unexpected findings include negative relationships between functional diversity, team and team leader Kaizen event experience, and action orientation and one or more outcomes. However, many of the findings confirmed recommendations in Kaizen event practitioner articles and the project and team literature. Furthermore, support for the mediation hypothesis was found for most outcome measures. These findings will be useful both for informing Kaizen event design in practicing organizations and for informing future Kaizen event research. / Ph. D.

Este trabalho busca apresentar um modelo de análise e projeto de layout industrial para empresas que estão implantando ou já implantaram os conceitos da Produção Enxuta. O modelo desenvolvido foca empresas de manufatura discreta em ambientes com uma alta variedade de produtos. O desenvolvimento do modelo foi elaborado com base na literatura técnica e na experiência prática em projetos de layouts desenvolvidos em diversas empresas. O objetivo principal desse trabalho foi desenvolver um modelo de fácil utilização que auxilie as pessoas envolvidas no projeto do arranjo físico. Esse modelo concebido utiliza ferramentas e conceitos da Produção Enxuta para analisar e projetar o novo layout, e como tal, não considera o layout como uma variável independente no sistema produtivo. Fatores como gestão visual, qualidade, fluxo contínuo, complexidade de programação da produção, entre outros, foram levados em consideração na construção do modelo. Este também incorpora uma metodologia de implantação do arranjo físico projetado em situações brown field, ou seja, com a fábrica em funcionamento. Esse ponto é de extrema importância pois alterações do layout podem incorrer em interrupções no fluxo produtivo e, conseqüentemente, em falhas na entrega dos produtos aos clientes. Por último, esse trabalho apresenta a metodologia 3P Kaizen, uma metodologia de projeto de layout industrial desenvolvida pela Toyota e utilizada em situações de projeto de novas fábricas ou de novas linhas de produção. / This work aims to show a model to analyze and design an industrial layout for companies that are implementing or have implemented lean manufacturing concepts. The model developed has a focus in discrete manufacturing companies in environments of high variety of products. The development of the model was based on the experience of layouts projects developed in many companies. The main aim of this work is to create an easy model of application that help people that are involved in the design of the facilities resources. This model utilizes tools and concepts of lean manufacturing to analyze and design a new layout, without considering the layout as an independent variable of production system. Aspects like visual management, quality, continuous flow, etc., were considered in the construction of the model. The layout design model presents also a methodology to implement a new layout projected in brown field situations, where the factory activities do not need to stop its activities. This point is very important because changing in the position of facilities resources can cause interruption in the flow of products. At last, this work shows the 3P Kaizen, a Japanese methodology, developed by Toyota, to design a layout of a new factory or a new production line.

Este trabalho busca apresentar um modelo de análise e projeto de layout industrial para empresas que estão implantando ou já implantaram os conceitos da Produção Enxuta. O modelo desenvolvido foca empresas de manufatura discreta em ambientes com uma alta variedade de produtos. O desenvolvimento do modelo foi elaborado com base na literatura técnica e na experiência prática em projetos de layouts desenvolvidos em diversas empresas. O objetivo principal desse trabalho foi desenvolver um modelo de fácil utilização que auxilie as pessoas envolvidas no projeto do arranjo físico. Esse modelo concebido utiliza ferramentas e conceitos da Produção Enxuta para analisar e projetar o novo layout, e como tal, não considera o layout como uma variável independente no sistema produtivo. Fatores como gestão visual, qualidade, fluxo contínuo, complexidade de programação da produção, entre outros, foram levados em consideração na construção do modelo. Este também incorpora uma metodologia de implantação do arranjo físico projetado em situações brown field, ou seja, com a fábrica em funcionamento. Esse ponto é de extrema importância pois alterações do layout podem incorrer em interrupções no fluxo produtivo e, conseqüentemente, em falhas na entrega dos produtos aos clientes. Por último, esse trabalho apresenta a metodologia 3P Kaizen, uma metodologia de projeto de layout industrial desenvolvida pela Toyota e utilizada em situações de projeto de novas fábricas ou de novas linhas de produção. / This work aims to show a model to analyze and design an industrial layout for companies that are implementing or have implemented lean manufacturing concepts. The model developed has a focus in discrete manufacturing companies in environments of high variety of products. The development of the model was based on the experience of layouts projects developed in many companies. The main aim of this work is to create an easy model of application that help people that are involved in the design of the facilities resources. This model utilizes tools and concepts of lean manufacturing to analyze and design a new layout, without considering the layout as an independent variable of production system. Aspects like visual management, quality, continuous flow, etc., were considered in the construction of the model. The layout design model presents also a methodology to implement a new layout projected in brown field situations, where the factory activities do not need to stop its activities. This point is very important because changing in the position of facilities resources can cause interruption in the flow of products. At last, this work shows the 3P Kaizen, a Japanese methodology, developed by Toyota, to design a layout of a new factory or a new production line.

A Kaizen event is a focused and structured improvement project, using a dedicated cross-functional team to improve a targeted work area, with specific goals, in an accelerated timeframe. Kaizen events have been widely reported to produce positive change in business results and human resource outcomes. However, it can be difficult for many organizations to sustain or improve upon the results of a Kaizen event after it concludes. Furthermore, the sustainability of Kaizen event outcomes has received limited research attention to date. This research is based on a field study of 65 events across eight manufacturing organizations that used survey data collected at the time of the event and approximately nine to eighteen months after the event. The research model was developed from Kaizen event practitioner resources, Kaizen event literature, and related process improvement sustainability and organizational change literature. The model hypothesized that Kaizen Event Characteristics, Work Area Characteristics, and Post-Event Characteristics were related to Kaizen event Sustainability Outcomes. Furthermore, the model hypothesized that Post-Event Characteristics would mediate the relationship between Kaizen Event and Work Area Characteristics and the Sustainability Outcomes. The study hypotheses were analyzed through multiple regression models and generalized estimating equations were used to account for potential nesting effects (events within organizations). The factors that were most strongly related to each Sustainability Outcome were identified. Work Area Characteristics learning and stewardship and experimentation and continuous improvement and Post-Event Characteristics performance review and accepting changes were significant direct or indirect predictors of multiple Sustainability Outcomes and these findings were generally supported by the literature. There were also some unanticipated findings, particularly regarding the modeling of Sustainability Outcomes result sustainability and goal sustainability, which appear to illustrate potential issues regarding how organizations define and track the performance of Kaizen events over time and present areas for future research. Overall, this study advances academic knowledge regarding Kaizen event outcome sustainability. The findings also present guidelines so that practitioners may better influence the longer-term impact of Kaizen events on their organizations. The research findings may also extend to other improvement activities, thus presenting additional areas for future work. / Ph. D.

Due to an extremely competitive market in recent years, the sector of aviation industry requires speed and agility to meet their external customers needs. To be competitive, it is necessary to produce parts that will make a quality product quickly in a way to reduce costs and increase agility in manufacturing. This dissertation presents a case study conducted in an industry of the aerospace segment with the purpose of finding alternatives for productivity gain, using lean thinking tools, specially the kaizen events (KE), in the development of machining programs for CNC machines, interconnected by CAD-CAM software. This method has been used with success in several industries leading to efficiency gains in solving problems of productivity, at low cost. During the implementation of KE, the work team implemented the value stream mapping (VSM), as an attempt to increase the value added in the preparation of the machining program and to meet the needs of the internal customer (production department). By using this methodology it was possible to reduce the average time of the development cycle of the NC programs in approximately 50% and the average number of hours spent to create the programs was also reduced in approximately 51%. Among several opportunities found during the preparation of current VSM, one of the major contributions to the productivity improvement resulted from the adoption of the continuous working flow practice. / Com o mercado extremamente competitivo nos últimos anos, o setor da indústria aeronáutica necessita de agilidade e rapidez para atender às necessidades dos clientes externos. Para ser competitivo torna-se necessário produzir peças que irão compor o produto rapidamente e com qualidade, de forma a reduzir os custos e aumentar a agilidade na fabricação. Esta dissertação apresenta um estudo de caso realizado numa indústria do segmento aeronáutico com o objetivo de encontrar alternativas para obter ganhos de produtividade no desenvolvimento de programas de usinagem para máquinas CNC, interligadas a softwares CAD-CAM, por meio da aplicação de ferramentas do pensamento enxuto, com ênfase em eventos Kaizen (EK). Este método esta sendo utilizado em várias indústrias com êxito e proporcionando ganhos de eficiência na solução de problemas de produtividade, com custo baixo. Durante a execução do EK, a equipe de trabalho implementou o mapeamento do fluxo de valor (MFV), buscando aumentar o valor agregado na elaboração do programa de usinagem, visando atender às necessidades do cliente interno (produção). A aplicação da metodologia tornou possível reduzir o tempo médio do ciclo de desenvolvimento da programação CN em aproximadamente 50% e o número médio de horas gastas para a criação dos programas em aproximadamente 51%. Dentre as diversas oportunidades encontradas durante a elaboração do MFV atual, destaca-se a criação dos programas de usinagem em fluxo contínuo para a obtenção destas melhorias.

A continuous improvement project (CIP) is a structured improvement project using a team of people "typically representing different departments or units in the organization" working to improve a process or work area over a relatively short period of time, such as a few days or up to several months. A CIP may use different improvement methodologies and tools, and may thus be defined according to the improvement approach. For instance, an organization adopting Lean as an improvement approach is likely to have CIPs implementing Lean tools, such as 5S or value stream mapping. These projects may be referred to as Lean projects in general, although they may also represent accelerated improvement projects such as Kaizen events, Kaizen blitz, or rapid improvement projects. Alternatively, an organization utilizing Six Sigma as an improvement approach may have Six Sigma projects that use the Define-Measure-Analyze-Improve-Control (DMAIC) process and statistical tools. Some organizations adopt an integrated improvement approach, such as Lean Six Sigma, and therefore may have CIPs with an even broader set of tools from which to choose. Lastly, many organizations may have an improvement approach not characterized by any single set of improvement processes and tools, and thus, may be thought of generally as process improvement, or quality improvement, projects using a traditional methodology as plan-do-study/check-act (PDSA or PDCA). In this dissertation, all of these types of improvement projects are referred as CIPs. Since the 1980s, hospitals have been using CIPs to address some of the problems in hospitals, such as quality in healthcare delivery, internal process efficiency, communication and coordination, and the cost of services. Some hospitals have achieved significant improvements, such as reducing the turnaround time for clinical laboratory results by 60 percent and reducing instrumentation decontaminations and sterilization cycle time by 70 percent. However, as with many other companies, hospitals often experience difficulty achieving their desired level of improvements with CIPs. Therefore, the purpose of this dissertation is to identify the critical success factors (CSFs) related to CIP success. In order to achieve this goal, five objectives were achieved: creating a methodology to assess the maturity or evolution of a research field (manuscript #1), identifying a comprehensive list of CSFs for CIPs (manuscript #2), assessing the maturity of the published literature on CIPs in hospitals (manuscript #3), identifying the most important factors related to CIPs in hospitals (manuscript #4) , and conducting an empirical investigation to define the CSFs for CIPs in hospital settings (manuscript #5 and #6). This investigation was conducted in three phases: research framing, variable reduction, and model development and testing. During these phases, the researcher used the following methodologies and data collection tools: systematic literature review, maturity framework (developed as part of this dissertation), expert study, retrospective survey questionnaire, exploratory factor analysis, partial-least squares structural equation modeling, and regression modeling. A maturity framework with nine dimensions was created (manuscript #1) and applied in order to identify a list of 53 factors related to CIP in general, involving any organization (manuscript #2). Additionally, the maturity framework was used to assess the literature available on CIPs in hospitals, considering only the authorship characteristic dimension (manuscript #3). Considering the frequency of new authors per year, the relative new integration of research groups, and the limited set of predominant authors, the research field, or area, of CIPs in hospitals is one with opportunities for improving maturity. Using the systematic literature review from manuscript #3, the list of 53 factors, and the list of predominant authors, a review of the literature was conducted, along with an expert study to more fully characterize the importance of various factors (manuscript #4). A conclusion from this particular work was that it is not possible to reduce the list of 53 factors based on these results, thus, a field study using the complete comprehensive list of factors was determined to have stronger practical implications. A field study was conducted to identify factors most related to CIP perceived success (manuscript #5) and CIP goal achievement (manuscript #6). The final results and practical implications of this dissertation consist in the identification of the following CSFs for CIP success in hospitals: Goal Characteristics, Organizational Processes, Improvement Processes, and Team Operation. These CSFs include several specific factors that, to the researcher's knowledge, have not been previously studied in empirical investigations: goal development process, organizational policies and procedures, CIP progress reporting, and CIP technical documentation. Practitioners involved with CIPs, such as CIP leaders, facilitators, stakeholders/customers, and continuous improvement managers/leaders, can utilize these results to increase the likelihood of success by considering these factors in planning and conducting CIPs. / Ph. D.

O movimento Lean vem crescendo significativamente no Brasil e no mundo. Os métodos enxutos para o desenvolvimento e a fabricação de produtos, do preenchimento do pedido à entrega, gerenciamento do fluxo de suprimentos, suporte a clientes e administração de toda a empresa agora são bem conhecidos e amplamente aceitos como conceito. Tal sucesso despertou o interesse das organizações em implantar o sistema de produção oriundo da Toyota. Entretanto, o que se observa é que poucas atingem resultados tão expressivos quanto os da montadora japonesa. A grande maioria não consegue garantir a sustentabilidade da manufatura enxuta em si, tanto em termos de como manter o impulso inicial, uma vez que os eventos Kaizen \"pilotos\" estão completos, quanto em como os membros da organização podem realmente desenvolver as suas capacidades de implantação do Lean. O que foi identificado é que, impulsionados pelo desempenho superior alcançado pelos produtores \"enxutos\" sobre os resultados obtidos com os modelos tradicionais do sistema de produção em massa, os fabricantes ocidentais reproduziram suas técnicas de chão de fábrica, ou seja, as partes estruturais do Lean, mas muitas vezes encontraram dificuldades para introduzir a cultura organizacional e a mentalidade pertinente a este sistema. Este trabalho propõe um conjunto de melhores práticas para a sustentação de eventos Kaizen nas implantações de Produção Enxuta buscando eliminar as lacunas identificadas entre outras propostas desse tipo e as necessidades encontradas em ambientes de Produção Enxuta reais. O conjunto de melhores práticas é baseado no levantamento bibliográfico da literatura técnica sobre o tema e na realização de pesquisa junto a uma empresa multinacional, localizada no Estado de São Paulo, reconhecidamente bem-sucedida na implantação e na sustentabilidade da Produção Enxuta em suas operações. Assim, o resultado encontrado foi o de identificação, aprimoramento e, em alguns casos, elaboração de práticas/ferramentas que facilitem a obtenção da sustentabilidade de eventos Kaizen nas implantações de Produção Enxuta. / The Lean movement has grown significantly in Brazil and worldwide. Lean methods to the development and manufacturing of products, since the order fulfillment until its delivery, through the supply chain management, the customer services and all the business administration activities are now well known and widely accepted as concepts. Such success has garnered interest from organizations in implementing the production system developed in Toyota. However, what is observed is that few achieve results as expressive as those of the Japanese automaker. The vast majority can not guarantee the sustainability of lean manufacturing itself, both in terms of keeping up the initial movement since the \"pilots\" Kaizen events are complete, as in, how members of the organization can really develop their skills of implementing Lean. What has been identified is that driven by the superior performance achieved by the lean producers over the results obtained with traditional models of the mass production system, Western manufacturers reproduced their shop floor techniques, in other words, the structural parts of Lean, but often found it difficult to introduce the organizational culture and mentality which are relevant to this system. This dissertation proposes a set of best practices for supporting Kaizen events in the implementation of Lean Production seeking to eliminate the identified gaps between other proposals found in literature and the requirements identified in real shop floor environments. The set of best practices is based on the review of technical literature on the subject and in a field research with a multinational company, located in the State of São Paulo, recognized for the successful implementation and sustainability of lean production in their operations. Thus, the result was the identification, enhancement and, in some cases, development of practices/tools to facilitate the achievement of sustainability of Kaizen events in implementations of Lean Production.

Made available in DSpace on 2015-04-22T22:11:22Z (GMT). No. of bitstreams: 1 Alberjan.pdf: 1648406 bytes, checksum: e7cc01faadea0adae547a7958b75ccce (MD5) Previous issue date: 2011-07-15 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / This work was aimed at applying the tools of the PRS System (Lean Production), whose primary tool was crafted VSM (Value Stream Mapping), a process known as SMT (Surface Mount Technology). Principles for lean production, eliminating waste and creating value stream in a real situation through kaizen events, were used to obtain results of this application, showing a lean transformation, with significant reductions in waste generated in the process. The study period was eight months into a private company located in PIM, where through the use of tools of this system and methodology of action research, it was possible to identify the critical process - setup - where focused improvement actions. With the change in the system setup, the standard work and creating a setup program using visual aid, favoring the continuous flow in this process. During the research, trainings were conducted in the factory with the operators, leaders, supervisors and engineers responsible, who participated actively in the improvement actions. Therefore, through value stream mapping, we propose to draw the current state of the stream, offering a future state, identifying and eliminating everything does not add value. To quantify the increase in productivity on the factory floor and total earnings of areas in the factory. / Este trabalho teve como objetivo a aplicação das ferramentas do Sistema de Produção Enxuta (SPE), cuja principal ferramenta trabalhada foi o Mapeamento da cadeia de valor (VSM), num processo denominado Tecnologia em Montagem de Superfície (SMT). Princípios que regem a produção enxuta, eliminação de desperdícios e a criação do fluxo de valor em uma situação real, através de eventos kaizen, foram utilizados para a obtenção de resultados dessa aplicação, evidenciando uma transformação enxuta, com expressivas reduções dos desperdícios gerados no processo. O período da pesquisa foi de oito meses em uma empresa privada situada no PIM, onde por meio da utilização de ferramentas desse sistema e a metodologia da pesquisa-ação, foi possível identificar o processo crítico setup para onde se concentraram as ações de melhorias. Com a mudança na sistemática de setup, no trabalho padronizado e criação de um setup programado, utilizando indicações visuais, favorecendo o fluxo contínuo nesta cadeia produtiva. No desenvolvimento da pesquisa, foram realizados treinamentos in loco com os operadores, líderes, supervisores e os engenheiros responsáveis, os quais participavam ativamente nas ações de melhoria. Portanto, através do mapeamento da cadeia de valor, propõem-se desenhar o estado atual da cadeia, propondo um estado futuro, identificando e eliminando aquilo que não agrega valor. Com isso, quantificar o aumento na produtividade no chão de fábrica e ganhos totais de áreas na fábrica.

O movimento Lean vem crescendo significativamente no Brasil e no mundo. Os métodos enxutos para o desenvolvimento e a fabricação de produtos, do preenchimento do pedido à entrega, gerenciamento do fluxo de suprimentos, suporte a clientes e administração de toda a empresa agora são bem conhecidos e amplamente aceitos como conceito. Tal sucesso despertou o interesse das organizações em implantar o sistema de produção oriundo da Toyota. Entretanto, o que se observa é que poucas atingem resultados tão expressivos quanto os da montadora japonesa. A grande maioria não consegue garantir a sustentabilidade da manufatura enxuta em si, tanto em termos de como manter o impulso inicial, uma vez que os eventos Kaizen \"pilotos\" estão completos, quanto em como os membros da organização podem realmente desenvolver as suas capacidades de implantação do Lean. O que foi identificado é que, impulsionados pelo desempenho superior alcançado pelos produtores \"enxutos\" sobre os resultados obtidos com os modelos tradicionais do sistema de produção em massa, os fabricantes ocidentais reproduziram suas técnicas de chão de fábrica, ou seja, as partes estruturais do Lean, mas muitas vezes encontraram dificuldades para introduzir a cultura organizacional e a mentalidade pertinente a este sistema. Este trabalho propõe um conjunto de melhores práticas para a sustentação de eventos Kaizen nas implantações de Produção Enxuta buscando eliminar as lacunas identificadas entre outras propostas desse tipo e as necessidades encontradas em ambientes de Produção Enxuta reais. O conjunto de melhores práticas é baseado no levantamento bibliográfico da literatura técnica sobre o tema e na realização de pesquisa junto a uma empresa multinacional, localizada no Estado de São Paulo, reconhecidamente bem-sucedida na implantação e na sustentabilidade da Produção Enxuta em suas operações. Assim, o resultado encontrado foi o de identificação, aprimoramento e, em alguns casos, elaboração de práticas/ferramentas que facilitem a obtenção da sustentabilidade de eventos Kaizen nas implantações de Produção Enxuta. / The Lean movement has grown significantly in Brazil and worldwide. Lean methods to the development and manufacturing of products, since the order fulfillment until its delivery, through the supply chain management, the customer services and all the business administration activities are now well known and widely accepted as concepts. Such success has garnered interest from organizations in implementing the production system developed in Toyota. However, what is observed is that few achieve results as expressive as those of the Japanese automaker. The vast majority can not guarantee the sustainability of lean manufacturing itself, both in terms of keeping up the initial movement since the \"pilots\" Kaizen events are complete, as in, how members of the organization can really develop their skills of implementing Lean. What has been identified is that driven by the superior performance achieved by the lean producers over the results obtained with traditional models of the mass production system, Western manufacturers reproduced their shop floor techniques, in other words, the structural parts of Lean, but often found it difficult to introduce the organizational culture and mentality which are relevant to this system. This dissertation proposes a set of best practices for supporting Kaizen events in the implementation of Lean Production seeking to eliminate the identified gaps between other proposals found in literature and the requirements identified in real shop floor environments. The set of best practices is based on the review of technical literature on the subject and in a field research with a multinational company, located in the State of São Paulo, recognized for the successful implementation and sustainability of lean production in their operations. Thus, the result was the identification, enhancement and, in some cases, development of practices/tools to facilitate the achievement of sustainability of Kaizen events in implementations of Lean Production.

Organizational communication research indicates group member participation increases as the legitimate power differences among group members decreases. Lean principles and practices indicate Kaizen Event members will contribute regardless of legitimate power levels, due to member training, education, and the Lean team-oriented culture. Further study is needed to determine if Lean culture and training maximize group member contribution, or if legitimate power levels in Lean environments manipulate participation. The focus of this case study is a central Kentucky Lean manufacturing organization that practiced Lean principles for at least three years and completed a Kaizen Event within twelve months previous to the beginning of the study. The participating organization indicated the legitimate power levels of Kaizen Event members. Kaizen Event members received a voluntary survey consisting of Likert scalescored questions regarding his or her perceptions of level of participation, encouragement and opportunity to participate, comfort in participating, and the degree the group listened to the member. The results of the survey indicated participation in the Kaizen Event groups did not significantly differ among different legitimate power levels.