<p>Due to a constantly increasing competitive pressure it is of great importance to constantly strive for improvements in order to gain competitive advantages. Lean Production is a concept that has been introduced with the aim to minimize waste and increase profitability. The purpose of this report is therefore to investigate how to perform effective planning according to the principles of Lean Production, in companys with customer exclusive products, through a case study at Sandvik Mining and Construction (SMC), and to investigate how SMC kan improve their planning of drifting rods at the production unit in Sandviken.</p><p>The study started by creating a theoretical framework, to describe the subject planning and planning based on Lean Production. This frame work constituted the base for the case study which took place at Sandvik Mining and Construction, and also for the model and planning tool that has been introduced.</p><p>The result of the study is partly a general model with factors that contribute to a more effective planning. These factors has beed identifed as SMED, which focuses on reducing set up times and in the end to facilitate the planning. With the assistance of the Pareto rule the amount of items can be grouped together and by that simplify production planning. By using the EOQ, optimized order quantities can be calculated, and thereby simplify for production planning. Even the degree of customer order management is something that affects how the planning can be managed as a high degree of customer order management can simplify for the decision making regarding wich product should be produced, however the time through production can increase. Sequensing is another method that simplifies the planning, as an already predetermined production order shall be produced. The most essential factor is however the motivation of the employees, as this forms the base to able other changes and implement them. Altogether these factors are closely connected to each other and working actively with these can contribute with a simplified planning procedure.</p><p>From without this a tool has been presented in order to simplify the planning of drifting rods at Sandvik Mining and Construction. Through this tool SMC can create a smoother flow through production, a smoother work load, a smoother machine load in the different assembly lines, and in the end reduced adjustment times within the forging press.</p> / <p>I dagens allt mer konkurrensutsatta samhälle är det av största vikt att hela tiden sträva efter förbättringar för att på så sätt vinna konkurrensfördelar. Lean Production är ett koncept som tagits fram med syftet att minimera slöseri och på så sätt öka lönsamheten. Syftet med detta examensarbete är att undersöka hur en effektiv planering enligt Lean’s principer kan bedrivas och tillämpas för verksamheter med kundunika produkter genom en fallstudie på Sandvik Mining and Construction (SMC), samt undersöka hur SMC kan förbättra sin planering av drifterstänger vid produktionsenheten i Sandviken.</p><p>Studien startade med att skapa en teoretisk referensram, för att beskriva ämnet planering och planering utifrån Lean Production. Denna referensram låg sedan tillgrund för den fallstudie som utfördes på Sandvik Mining Construction samt även för den modell och det verktyg som tagits fram.</p><p>Resultatet av studien är dels en generell modell med faktorer som bidrar till en effektivare planering. Dessa faktorer har identifierats som SMED, vilken fokuserar på att mininmera ställtider och på så sätt underlätta för planeringen. Med hjälp av paretoregeln kan antalet artiklar grupperas och genom detta förenkla produktionsplaneringen. Genom att räkna ut ekonomiska orderkvantiteter kan optimala orderstorlekar tas fram och därmed underlätta för planeringen. Även graden av kundorderstyrning är något som påverkar hur planeringen kan hanteras, då hög grad av kundorderstyrning underlättar för beslutsfattande gällande vilken produkt som skall produceras, däremot kan genomloppstiden öka. Sekvensering är en annan metod som underlättar för planeringen, då en redan förutbestämd produktionsordning skall köras. Den mest väsentliga faktorn är dock medarbetarnas motivation, då denna ligger till grund för att kunna genomföra de övriga. Samtliga faktorer har starka samband och ett aktivt arbete med dessa kan bidra till att planeringsarbetet förenklas.</p><p>Utifrån detta har ett verktyg tagits fram för att underlätta för planeringen av drifterstänger hos Sandvik Mining Construction, i Sandviken. Genom detta verktyg kan SMC skapa ett jämnare flöde genom produktionen, en jämnare arbetsbelastning, de får en jämnare beläggning på de olika tillverkningslinjerna, samt färre omställ inom smidespressen.</p>

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<p>Abstract</p><p>Lean production has become one common concept within industries to make the work more effective and to meet today’s hard competition. A challenge for Chinese production is the threat from new low cost countries. It will become very difficult to succeed to produce to a lower cost than these countries; this led to that Chinese companies must develop new strategies, according to Lee and Zhou (2000). This will put China in front of new challenges and new strategies can be needed to retain their strong competitive advantages. Can Lean production lead to advantages for Swedish companies with production in China?</p><p>Our aim with this study is to examine conditions in order to apply Lean production in China, to respond to this we have selected and looked closer to three Swedish companies with production in China and their work with Lean production. And which obstacles and success factors the companies have notice.</p><p>As a base to this study we have a literature study. The literature study lies as a ground for the case studies and our analysis of the aim and those questions we formulated. The three companies we have visited are of various sizes and that influences its sights on Lean production and thereby is given a variation to our study with different thoughts and opinions. The companies we visited are Habia Cable Changzhou, Nanjing Ericsson panda Communications Company Ltd and SKF Shanghai Automotive Technologies Co., Ltd, they are all located in China. At the companies we have done observations and interviews.</p><p>Four of the tools within Lean production have in one or another way been used in all case companies. These are SMED, 5S, standardization work and process mapping. Process mapping is the tool that is implemented in all companies. One of the bases to Lean production is involved leaderships; this is an important part that also shows in this study. All companies say that the weight of the employees and their attitude is an important part in the work with Lean production. The study confirms thereby that works on improvement are imported and also of the attitude and commitments of the employees. There are several obstacles for a work with Lean production in China, but with a long term thinking and patience with implementation, motivated managers and employees there will be a lot to win.</p>

<p>This graduation work is a result of implementing Lean Production using OEE and SMED at Enics Sweden AB in Malmö. Enics doesn’t have an established improvement concept and therefore should this work serve as an introduction to possibly start with Lean Production. A result in this report is that an OEE value has been identified within a common order at Enics. Other results are that an implementation of a Lean-board has been implemented and furthermore, within SMED, a flag that indicates changeover.</p> / <p>Enics AB är ett av många företag som producerar kretskort i Sverige och runt om i världen. Detta kräver att de kan producera med ett så högt utnyttjande som är möjligt för att vara konkurrenskraftiga mot andra tillverkare av kretskort. Ytmonteringslinan är den mest kapitalintensiva investeringen hos Enics och är därför den process som kräver mest utnyttjande.</p><p>När examensarbetet började hade Enics inget korrekt mått på den totala utrustningseffektiviteten (TAK) och de nådde sällan upp till sitt mål på utnyttjandegraden. De största förlusterna var tidsförluster i form av långa ställtider. För att öka utnyttjandegraden började de försöka tänka Lean runt om ytmonteringslinan även om Lean inte är något fastställt koncept på Enics. Med denna bakgrund togs ett syfte fram för examensarbetet. Syftet var att få ett korrekt uppmätt värde på den totala utrustningseffektiviteten samt att genom en metod för ställtidsreducering kallad SMED, sänka ställtiderna och därmed öka utnyttjandegraden.</p><p>Enics ville även att arbetet skulle ge dem en bas till framtida arbete med SMED och Lean Production. Genom olika mätningar med hjälp av tidsur, intervjuer och spagettidiagram kunde olika analyser göras såsom värdeflödesanalys, Ishikawadiagram och analys av observationer under, innan och efter ställ. Analyserna resulterade i ett antal förbättringsförslag där vissa av dem implementerades, vissa hamnade under utvärdering och vissa hamnade som framtida förbättringar.</p><p>Resultatet av examensarbetet gav positiva reaktioner från anställda på Enics. Enics har tagit till sig ett flertal av förslagen som tagits fram under detta arbete och användningen av förslagen ses som ett fortsatt arbete med Lean Production, SMED och TAK. Inom TAK har Enics genom detta examensarbete fått ett värde uträknat på sin totala utrustningseffektivitet. Inom Lean Production har Enics fått en tavla där gjorda förbättringar kan redovisas och förslag till förbättringar noteras. Inom SMED har examensarbetet resulterat i bl.a. en ställflagga som indikerar att intern ställtid har börjat, vilket har resulterat till att operatörer uppmärksammar ställ lättare och arbetar mer som ett lag.</p>

<p><em>Purpose</em>: this thesis study aims to provide an analysis and an assessment of the current operations’ performance effectiveness at Nobel Biocare’s production plant in Karlskoga, Sweden and to describe the potential for improvement. It intends to clarify the importance of performance measurement and explain Overall Equipment Effectiveness (OEE) metrics in particular.Furthermore, it strives to identify causes for inefficiency in production and suggest recommendations to minimize losses.</p><p><em>Methodology:</em> the study is using both qualitative and quantitative approaches in parallel as measurements are implemented to discover effectiveness rates and detect causes for production losses while assessments are made using different models, such as the Capability Maturity Model(CMM) and OEE assessments, in order to evaluate the current development level and the potential for improvement.</p><p><em>Findings:</em> the research finds that major losses are closely related to frequency of changeovers in machining processes, where average effectiveness rates were 68%. In surface treatment and packaging equipment inspected, the values were found to be between 46% and 59% as the major common cause was the absence of work due to unstable flow of orders. Assessing process orientation and maturity levels, the findings indicate on high levels in general. However, areas of weakness were identified in the different processes in which the potential for improvement is embedded. In those areas, lower OEE values were registered; low levels of maturity and process orientation were found, as low development of losses improvement were assessed. The study finally suggests that the areas of weakness suffer from lack of learning orientation that is ought to be improved and at the same time, a variety of specific recommendations are provided.</p>

<p>Purpose:this thesis study aims to provide an analysis and an assessment of the current operations’ performance effectiveness at Nobel Biocare’s production plant in Karlskoga, Sweden and to describe the potential for improvement. It intends to clarify the importance of performance measurement and explain Overall Equipment Effectiveness (OEE) metrics in particular. Furthermore, it strives to identify causes for inefficiency in production and suggest recommendations to minimize losses.</p><p>Methodology: the study is using both qualitative and quantitative approaches in parallel as measurements are implemented to discover effectiveness rates and detect causes for production losses while assessments are made using different models, such as the Capability Maturity Model(CMM) and OEE assessments, in order to evaluate the current development level and the potential for improvement.</p><p>Findings: the research finds that major losses are closely related to frequency of changeovers in machining processes, where average effectiveness rates were 68%. In surface treatment and packaging equipment inspected, the values were found to be between 46% and 59% as the major common cause was the absence of work due to unstable flow of orders. Assessing process orientation and maturity levels, the findings indicate on high levels in general. However, areas of weakness were identified in the different processes in which the potential for improvement is embedded. In those areas, lower OEE values were registered; low levels of maturity and process orientation were found, as low development of losses improvement were assessed. The study finally suggests that the areas of weakness suffer from lack of learning orientation that is ought to be improved and at the same time, a variety of specific recommendations are provided.</p>

<p>This paper is about the new methods and metrics used in industry and business today striving for better revenues and larger market shares. It investigates the relations between the old fordistic and tayloristic way of manufacturing and compares it to the models used in industry today for being competitive, seeking to please customers and becoming more flexible. More specific the paper is about if Six Sigma and lean production are the key for succeeding these days. SKF:s factory in Gothenburg and other companies will make an example for how these methods are used in practice.</p><p>The aim is to try to answer if these systems with inherited tools and methods are the right way to get the flexibility that is needed for being able to deliver the right goods to customers and market. For a company to be flexible decisions must be made fast and needed changes must be able to be done easy and without too large costs and investments. Both in Six Sigma and lean production the total staff in a company is involved with quality matters and continuous improvements. This brings an atmosphere and a certain way to work that makes it possible to reach high defined goals and move towards a common vision. Flexibility can be reached in both production and in developing new products when a company has an atmosphere that makes it possible for all personnel to talk the same language and strive for the same thing. Six Sigma and lean production have the possibility to achieve a higher level of flexibility, that is, when being applied in right places in the right way.</p>

Does a manufacturing company have to concentrate on a few competitive priorities or can it excel at everything it does? The traditional notion of trade-offs between manufacturing capabilities has recently come under question. Based on the manufacturing management practices of certain Japanese companies, or lean production, it has been proposed that manufacturing capabilities are built cumulatively. The sequence of the initiatives with which manufacturing capabilities are built has, however, received less attention. Particularly lacking are studies which take a process view of implementation. A process view implies studying implementation through longitudinal research, as opposed to cross-sectional research. This book addresses this gap in knowledge. The central problem examined in this book is whether there exists any sequences of lean production principles and what the sequences are. For a period of two and a half years, the author participated in and studied the transformation of Office Machines - the fictitious name of a company adopting lean production. Using the clinical methodology, the author gained access to data not normally available for research, which provided a unique opportunity to study the adoption process. The findings from the clinical study groups the principles of lean production into four different categories, depending on when management devoted effort and resources to the principles. Through a comparison with existing operations management theory, the study’s conclusions indicate that there are sequences in which lean production principles are adopted. However, management also need to devote effort and resources to a set of principles simultaneously. / <p>Diss. Stockholm : Handelshögsk.</p>

This paper is about the new methods and metrics used in industry and business today striving for better revenues and larger market shares. It investigates the relations between the old fordistic and tayloristic way of manufacturing and compares it to the models used in industry today for being competitive, seeking to please customers and becoming more flexible. More specific the paper is about if Six Sigma and lean production are the key for succeeding these days. SKF:s factory in Gothenburg and other companies will make an example for how these methods are used in practice. The aim is to try to answer if these systems with inherited tools and methods are the right way to get the flexibility that is needed for being able to deliver the right goods to customers and market. For a company to be flexible decisions must be made fast and needed changes must be able to be done easy and without too large costs and investments. Both in Six Sigma and lean production the total staff in a company is involved with quality matters and continuous improvements. This brings an atmosphere and a certain way to work that makes it possible to reach high defined goals and move towards a common vision. Flexibility can be reached in both production and in developing new products when a company has an atmosphere that makes it possible for all personnel to talk the same language and strive for the same thing. Six Sigma and lean production have the possibility to achieve a higher level of flexibility, that is, when being applied in right places in the right way.

The aim of remanufacturing is to retrieve a product’s inherent value when the product no longer fulfils the user’s desired needs. By taking advantage of this inherent value through different product recovery alternatives, there is a potential for both economically and environmental advantageous recovery of products. Remanufacturing is a complex business due to the high degree of uncertainty in the production process, mainly caused by two factors: the quantity and the quality of returned products. These factors have implications both on the external processes, e.g. coordinating input of returned products with the demand for remanufactured products, as well as the internal processes that coordinates the operations within the factory walls. This additional complexity needs to be considered when organising the remanufacturing system. The objective of this dissertation is to explore how remanufacturing companies can become more competitive through analysing and managing material flows and remanufacturing processes. The first issue discussed in this dissertation is the drivers that make companies interested in remanufacturing products in the first place. The conclusion is that the general drivers are profit, company policy and the environmental drivers. In a general sense, the profit motivation is the most prevalent business driver, but still there are situations where this motivation is secondary to policy and environmental drivers. Secondly, the need to balance the supply of returned products with the demand for remanufactured products shows that the possible remanufacturing volumes for a product are dependent on the shape of the supply and demand distributions. By using a product life cycle perspective, the supply and demand situations can be foreseen and support is given on possible strategies in these different supply and demand situations. Thirdly, how used products are gathered from customers is categorised by seven different customer relationship types. These types all have different effects on the remanufacturing system, and the characteristics of these relationships are disused in detail. When considering the remanufacturing process within the factory walls, a generic remanufacturing process was developed that divides the remanufacturing process into five different phases; pre-disassembly, disassembly, reprocessing, reassembly and the post-assembly phase. These different phases are separated by three different key decision points in the process that also have a major impact on the material planning of the process. For the remanufacturing material planning and production planning, the possibility to apply lean principles can be difficult. One foundation for implementing lean principles in new production is the existence of standardised processes that are stable and predictable. In the remanufacturing system, the possibilities to realise a predictable process is limited by the “normal” variations in quantity and the quality of the returned cores. Even though lean principles can be problematic to implement in the remanufacturing environment, this dissertation proposes a number of solutions that can be used to make the remanufacturing process leaner.