Cada vez mais presentes no ambiente industrial, as metodologias de melhoria contínua estruturam e sistematizam a implantação e a aplicação de técnicas, ferramentas e práticas de melhoria dos processos, que permitem reduzir o lead time, aumentar a satisfação do cliente, diminuir a variabilidade dos processos e elevar a qualidade do produto. Neste contexto, o objetivo deste trabalho é, com o auxílio de um framework teórico, estudar o uso de Lean Manufacturing e Six Sigma em um caso real pertencente ao parque industrial nacional. Dessa forma, optou-se por realizar um estudo de caso em uma empresa do ramo automobilístico, visto a relação do setor com a melhoria contínua. A companhia já utilizava as técnicas e ferramentas há mais de uma década e, além de mostrar a sua abordagem com relação à melhoria contínua de forma geral, apresentou dois casos para comparação das soluções encontradas para seu próprio aperfeiçoamento. Foi observado que a empresa encontra-se em um estágio intermediário-avançado dentro do framework construído e foi ressaltado que o Kaizen é a principal forma de melhoria usada. / Increasingly present in industrial environment, the continuous improvement methodologies structured and systematized the implementation and employment of techniques, tools and practices of process improvement, which allow reducing lead time, enhancing customer satisfaction, decreasing process variability and raising product quality. In this context, supported by a framework, what this study aims at is to review the use of Lean Manufacturing and Six Sigma in a real case belonging to the national industrial park. Hence, a case study was chosen in a company from the automotive industry, insofar as its relationship with continuous improvement. The company had already been using the techniques and tools for over a decade and it was provided an overview of its approach and, in addition, two cases to have their solution compared. It was observed that the company stands in an upper intermediate stage according to the developed framework and it was also highlighted that Kaizen is the main improvement means used.

The objective of this work is to tell the application of the administration model for process management, Lean manufacturing and online statistical process in a industry of coated and formed chicken products, seeking to evaluate the acting of the processes key of the business continually with the customer's vision. The study was made by the evaluation of the process improvement, accomplished by control charts and capability indexes, comparing the data before and after the implantation of the administration system for process associated to the statistical process control. This way, the collected data suggest that the new administration model, brought for this company a larger involvement of all the members of the organization, in the search of the reduction of losses and products out of the technical specifications and mainly a larger attendance the customer s technical specification, however the causes of variation of the process need to be better investigated / O objetivo deste trabalho é desenvolver um sistema de gestão por processos e lean manufacturing associado ao controle estatístico de processo online em uma indústria de produtos empanados a base de frango, visando avaliar continuamente o desempenho dos processos chave do negócio com a visão do cliente. O estudo foi feito pela avaliação da melhoria do processo, realizado mediante gráficos de controle e índices de capabilidade, comparando os dados antes e após a implantação do sistema de gestão por processos e lean manufacturing associado ao controle estatístico de processo. Desta forma, os dados coletados sugeriram que o novo sistema de gestão, trouxe para essa empresa, um maior envolvimento de todos os integrantes da organização, na busca da redução de perdas e produtos fora das especificações técnicas e principalmente, um maior atendimento das necessidades dos clientes; porém as causas de variação do processo precisam ser melhores investigadas

PSA Peugeot Citroën, a French automaker, has one plant in Brazil, located in Porto Real, Rio de Janeiro. This factory mounts 29 vehicles / hour of eight different models, four models of Peugeot and Citroën brand four. This great variety of models generates complexity in the production process and wide range of parts. This study aims to analyze the impact of diversity, illustrate wasteful standard concept of 3MUs (MUDA, MURI, MURA) and present a study of reducing overall diversity. This will be used to apply the tools and techniques of `Lean Manufacturing Concept. The Lean production system, which basically seeks to eliminate waste, presents several concepts that can and should be applied in studies of eliminating diversity. Among the concepts that can be used stand out studies Time and Methods, SMED, 5S, Kanban, Value Stream Mapping and Kaizen and Poka-Yoke. Through analysis of cases will demonstrate that reducing the diversity of parts and reduce costs, avoid waste and adding a number of benefits, impacts directly on the entire production chain of the automaker. The reduction of diversity interferes with logistics (transport, handling, storage, control), quality (robustness of process variability), production (surface, rework), systems (complex document base, variety of systems), engineering (equipment, investments, solutions) and suppliers (setups, inventories). Therefore, this work is of extreme importance and relevance for companies with a high level of competitiveness, such as assemblers, stay ahead in the job market and offer the best value for money offers. / A PSA Peugeot Citroën, montadora de origem francesa, possui uma única fábrica no Brasil, localizada em Porto Real, Rio de Janeiro. Essa fábrica monta 29 veículos/hora de oito modelos distintos, sendo quatro modelos da marca Peugeot e quatro da marca Citroën. Essa grande variedade de modelos gera uma complexidade no processo produtivo e grande diversidade de peças. Esta dissertação tem como objetivo analisar o impacto da diversidade, exemplificar os desperdícios no padrão do conceito dos 3MUs (MUDA, MURI, MURA) e apresentar um estudo de redução da diversidade geral. Para isso, será utilizada a aplicação das ferramentas e técnicas do `Lean Manufacturing Concept. O sistema de produção Lean, que basicamente busca a eliminação de desperdícios, apresenta diversos conceitos que podem e devem ser aplicados nos estudos de eliminação da diversidade. Entre os conceitos que podem ser utilizados, destacam-se Estudos de Tempos e Métodos, SMED, 5S, Kanban, Mapeamento de Fluxo de Valor e Poka-Yoke e Kaizen. Através da análise de casos, se mostra que a redução da diversidade de peças, além de reduzir custos, evitar desperdícios e agregar uma série de benefícios, impacta diretamente em toda a cadeia produtiva da montadora. A redução da diversidade interfere na logística (transporte, movimentação, armazenagem, controle), na qualidade (robustez do processo, variabilidade), na produção (superfície, retrabalhos), nos sistemas (complexa base documental, variedade de sistemas), na engenharia (equipamentos, investimentos, soluções) e nos fornecedores (setups, estoques). Portanto, a presente dissertação é de extrema importância e relevância para que empresas com alto nível de competitividade, como as montadoras, permaneçam a frente no mercado de trabalho e ofereçam as melhores ofertas de custo-benefício.

Lean strategy deployment (LSD) provides a means to create lasting value at reduced cost; yet most LSD efforts fail to attain sustainable improvements. The current study sought to gain an understanding of how leaders in oral healthcare manufacturing setting in the northeastern region of the United States can apply self-efficacy and leadership commitment during an LSD. Using Bandura’s theory of self-efficacy this qualitative phenomenological study examined the lived experiences and perceptions of 15 mid-to-senior level managers, concerning the use of self-efficacy and leadership commitment during a lean strategy deployment (LSD). The key findings resulted in 10 emergent themes. The top 3 highly regarded themes that emerged from this study were: (1) committing to a lean strategy deployment, (2) communicating lessons learned/changes, and (3) bringing the best out of employees. LSDs are not easy to implement. Many companies attempt to carry out lean activities and many of these same companies fail to have successful results. To be effective, leaders should focus on creating sound practices and give more attention to the human behaviors and leadership characteristics needed to support eliminating barriers and creating a lean culture.

La presente investigación examina la baja eficiencia en el procesamiento de frutos cítricos en la provincia de Huaral, Lima, Perú. La investigación se llevó a cabo con ayuda de artículos científicos en experiencia con la cadena de suministro, procesos y etapas especialmente en el sector agroindustrial. La contribución que aquí se propone es la disminución de desperdicios en la cadena de suministro mediante el uso de herramientas de Lean Manufacturing como 5S y Balance de línea. Finalmente, se simulará los procesos en una Mype y se distinguirán si las herramientas son las más factibles para el presente caso mediante los resultados obtenidos. Los resultados obtenidos luego de la simulación fueron un incremento en la eficiencia de 6.01%, reducción de merma de 6.70% y tiempo de ciclo de 47.15 minutos. / The present investigation examines the low efficiency in the processing of citrus fruits in the province of Huaral, Lima, Peru. The research was carried out with the help of scientific articles on experience with the supply chain, processes, and stages, especially in the agro-industrial sector. The contribution proposed here is the reduction of waste in the supply chain through the use of Lean Manufacturing tools such as 5S and Line Balance. Finally, the processes will be simulated in a Mype and it will be distinguished if the tools are the most feasible for the present case through the results obtained. The results obtained after the simulation were an increase in efficiency of 6.01%, reduction of waste of 6.70% and cycle time of 47.15 minutes. / Trabajo de investigación

El presente trabajo de investigación tiene como principal objetivo identificar, analizar y mejorar los principales procesos del servicio integral de sepelio en la empresa Servicios Funerarios Campo Fe SAC, para afrontar la creciente demanda por el Covid-19, con el fin de identificar y reducir las actividades que no generan valor al proceso, así como de optimizar todas aquellas actividades que sí generan valor, reduciendo desperdicios y logrando un proceso más esbelto, ganando mayor competitividad y reduciendo costos. El trabajo está compuesto por cinco capítulos: en el primer capítulo se desarrolla el estado del arte, marco teórico, casos de éxito y normatividad; en el segundo capítulo se procede a describir la situación actual de la empresa mediante el diagnóstico; en el tercer capítulo se expone la propuesta de mejora de los procesos; en el cuarto capítulo se muestra el impacto económico y la validación de la propuesta de mejora y por último en el capítulo cinco, se presentan las conclusiones y recomendaciones de la aplicación del presente trabajo de investigación. Para ello se utilizaron herramientas de Lean Manufacturing mejorando los tiempos de los principales procesos (Takt Time). Todo ello mostró una mejora en la organización de los espacios de trabajo (5S). La aplicación de la filosofía Lean redujo costos y mejoró la productividad de la empresa, con lo cual se alcanzó una disminución acumulada en el tiempo de servicio integral de sepelio. / The objective of this investigation is to identify, analyze and improve the main processes of the integral burial service in Campo Fe SAC, in order to help them face in a more appropriate way the growing demand for Covid-19. The focus is to identify and reduce the activities that do not generate value to the process, as well as to optimize all those activities that do generate value, reducing waste and achieving a leaner process, gaining greater competitiveness and reducing costs. This study has five chapters: the first chapter shows a summary of the state of the art, theoretical framework, success stories and regulations; the second chapter describes the current situation of the company through the diagnosis; the third chapter presents a proposal to improve the processes; the fourth chapter shows the economic impact and validation of the improvement proposal and the fifth chapter presents the conclusions and recommendations of the application of this research. The current work applies Lean Manufacturing tools to improve the time of the main processes (Takt time). Results showed an improvement in the organization of workspaces (5S). The application of Lean philosophy reduced costs and improved the productivity of the company, achieving a cumulative decrease in the comprehensive burial service time. / Trabajo de investigación

This study investigates the relationship between an increased traceability and shortened lead times in the internal material replenishment system at a large Swedish industrial tools manufacturer. Traceability and its effects on uncertainty in the supply chain has been widely researched in academia, but there is a gap regarding how traceability affects lead times. The research investigates which factors drive the lead times in the material replenishment to lean assembly lines and determines how these factors relate to traceability. A case study was conducted in one of the case company’s factories. The study consists of both quantitative and qualitative data. The quantitative data was derived from the case company’s ERP-system while the qualitative data consists of interviews and empirically collected data. The results of the study show that waiting time is the primary driver of lead times in the current state of the factory. No indication that internal material replenishment lead times decrease as a result of an increased traceability was found. However, there are aspects with an increased traceability that indirectly facilitates reduction of lead times by making it easier to make well-informed decisions due to the increased availability of real-time data. Traceability is found to not contribute any value to the end customer on its own. However, it can play an important role in a company’s supply chain. Further, potential advantages with a high traceability were observed when implementing advanced protocols such as JIT and other lean principles. The study should be seen as a starting point to further studies into the relationship between increasing traceability and reduced internal lead times. For managers and companies, the study identifies a potential procedure to use for deter- mining which factors drive replenishment lead times to lean assembly lines. Furthermore, the study shows that companies can have great use for traceability when trying to remove waste from its processes. / Denna rapport utreder sambandet mellan en ökad spårbarhet i den interna materi- altillförseln hos ett stort svenskt producerande företag och minskningen av dess ledtider. Forskning har bedrivits inom spårbarhet och kring dess effekter på osäkerheten i en sup- ply chain, men det finns begränsad forskning gällande spårbarhetens effekter på interna ledtider. I studien undersöks vilka faktorer som driver ledtiderna i materialtillförseln till lean mon- teringslinor hos ett producerande företag och hur en ökad spårbarhet påverkar dessa. En fallstudie har utförts hos ett industriföretag, i en av deras fabriker. Studien använ- der sig av både kvantitativ och kvalitativ data. Den kvantitativa datan kommer från fallstudieföretagets affärsystem medan den kvalitativa delen består av intervjudata och empiriskt genererad data. Resultatet av denna studie visar att det främst är väntetider som driver upp ledtiderna i fabriken. Inga bevis hittades för att interna materialtillförselns ledtider minskar som en direkt följd av en ökad spårbarhet. Däremot finns det aspekter med en ökad spårbarhet som hjälper att minska ledtiderna indirekt genom att underlätta för bättre underbyggda beslut som följd av en ökad tillgänglighet av data i realtid. Denna studie visar på att spårbarheten i sig inte skapar något värde för slutkunden, men att det trots det kan spela en viktig roll i företagets supply chain. Dessutom påvisas poten- tiella fördelar med en god spårbarhet när man implementerar avancerade system så som JIT och andra lean-principer. Rapporten bör ses som en startpunkt för framtida studier för att undersöka sambandet mellan en ökad spårbarhet och minskade ledtider. För företag så innebär denna rapport en möjlighet till att få en förståelse för vilka fak- torer som driver upp ledtiderna i materialtillförseln till lean monteringslinor. Dessutom visar studien på att företag kan gynnas av att öka sin spårbarhet när det gäller process- förbättringsarbete.

El presente estudio tuvo como objetivo incrementar el nivel de servicio en la empresa S&E INOXI S. A. C., la cual se dedica a fabricación y venta de muebles en acero inoxidable y brindar servicios de mantenimiento, ya que se encontraba en un escenario de pérdidas económicas equivalente a S/.28 470,00, debido a la penalización del 5% por incumplimiento de la fecha de entrega. Asimismo, existían pérdidas por materia prima de S/. 96 905,03. El presente trabajo propone una mejora del sistema productivo mediante la implementación de las herramientas de Lean Manufacturing para incrementar su nivel de servicio. Esto se logró mediante la ejecución de un diagnóstico de la situación actual del proceso de fabricación de trampa de sólidos y grasas, evaluación y determinación de los métodos y/o herramientas de ingeniería, seguidamente se elaboraron propuestas de mejora del proceso que contribuyeran a incrementar el nivel de servicio y finalmente se realizó el análisis costobeneficio del proyecto. Como resultado de la investigación se obtuvo un incremento del 23,1% en el nivel de servicio, se redujo la pérdida de materia prima en un 84,13%, esto mediante el incremento del 23,51% de la eficiencia física y se logró una disminución del 51,87% de la distancia recorrida. Además, se redujo el cuello de botella en un 10,64% y el tiempo de flujo del proceso en un 9,88%. También mediante las capacitaciones y el diagrama OT se consiguió la polivalencia del operario, consiguiendo la reducción de un 67,41% del tiempo ocioso para un lote de 3 unidades. / The objective of this study was to increase the level of service in the company S & E INOXI S. A. C., which is dedicated to manufacturing and selling stainless steel furniture and provide maintenance services, since it was in a scenario of economic losses equivalent to S/. 28 470,00, due to the penalty of 5% for breach of the delivery date. Likewise, there were losses by raw material of S/. 96 905,03. The present work proposes an improvement of the productive system through the implementation of Lean Manufacturing tools to increase its level of service. This was achieved through the execution of a diagnosis of the current situation of the manufacturing process of solids and grease traps, evaluation and determination of the methods and / or engineering tools, followed by proposals for improvement of the process that would contribute to increase the level of service and finally the cost-benefit analysis of the project was carried out. As a result of the research, an increase of 23,1% in the level of service was obtained, the loss of raw material was reduced by 84,13%, this by means of the increase of 23,51% of the physical efficiency and it was achieved a decrease of 5,.87% of the distance traveled. In addition, the bottleneck was reduced by 10,64% and the process flow time by 9,88%. Also through the trainings and the OT diagram, the polyvalence of the operator was achieved, achieving a reduction of 67,41% of idle time for a batch of 3 units.

This study explored the theoretical aspects of Lean Manufacturing principles and identified the practical implementations for a gold processing plant. The success rate of Lean implementations is currently as low as 5% and can be attributed to the failure of management to address the effect of implemented changes on the employees. With this risk in mind, the study included a measurement of the worker perception towards change and organisational climate. The impact of Lean Manufacturing principles was thus quantified by means of practical projects, including an empirical study of how open employees are towards change implementation. The plant process was described and the flow of value was mapped in a Value Stream Map (VSM). The applied principles resulted in three proposed improvement projects with the potential of reducing operating cost, generating additional revenue and eliminating waste. The proposals included reducing lead times through the plant for the two feed sources, namely reef and waste material by 4% and 51% respectively; improved recovery of fine carbon as a by-product of the treatment circuit; and lastly, reducing the lead time for conducted elusions by improving the “flow” of solution throughout the batch process. The quantified financial benefits of the improvements were an estimated additional revenue of R180,000 per month and a further cost saving of R4,000 per month. This study explained that multiple spin-off benefits are realized when improvements are based on Lean Manufacturing principles. Some additional benefits were listed but not quantified in this study. It is important to notice that these specific identified improvements did not require additional capital expenditure, nor long lead times to be implemented. Requirements included an open mind towards change management, time and effort. A survey was conducted to measure the employees’ readiness for change management and the stability of the organisational climate. In the South African mining context, there are external factors impacting on operations of which labor, unions and worker productivity are among the foremost aspects of current concern. This served as motivation for the survey to test employee readiness for Lean Manufacturing changes to be implemented. The statistical internal consistency of the questionnaire, as expressed by the Cronbach alpha coefficients, was acceptable at 0.773 and 0.759 for the change management and organisational climate factors respectively. The p-values and effect sizes were determined within the T-test and ANOVA tests. The group consisting of different years’ experience yielded the most statistical differences in the way that the organisational climate section was completed. The indication was that highly experienced employees answered the questionnaire significantly different than the other groups. The average scoring for the section was above the average and therefore was not considered to be a significant risk to implementation. The group is considered ready for change implementation and the plant should proceed to implement the identified Lean projects. The success and sustainability of the projects can encourage additional improvements. The recommendation is to revisit the future VSM after completion of the projects to identify the next level of improvements for implementation. / MBA, North-West University, Potchefstroom Campus, 2015

This study explored the theoretical aspects of Lean Manufacturing principles and identified the practical implementations for a gold processing plant. The success rate of Lean implementations is currently as low as 5% and can be attributed to the failure of management to address the effect of implemented changes on the employees. With this risk in mind, the study included a measurement of the worker perception towards change and organisational climate. The impact of Lean Manufacturing principles was thus quantified by means of practical projects, including an empirical study of how open employees are towards change implementation. The plant process was described and the flow of value was mapped in a Value Stream Map (VSM). The applied principles resulted in three proposed improvement projects with the potential of reducing operating cost, generating additional revenue and eliminating waste. The proposals included reducing lead times through the plant for the two feed sources, namely reef and waste material by 4% and 51% respectively; improved recovery of fine carbon as a by-product of the treatment circuit; and lastly, reducing the lead time for conducted elusions by improving the “flow” of solution throughout the batch process. The quantified financial benefits of the improvements were an estimated additional revenue of R180,000 per month and a further cost saving of R4,000 per month. This study explained that multiple spin-off benefits are realized when improvements are based on Lean Manufacturing principles. Some additional benefits were listed but not quantified in this study. It is important to notice that these specific identified improvements did not require additional capital expenditure, nor long lead times to be implemented. Requirements included an open mind towards change management, time and effort. A survey was conducted to measure the employees’ readiness for change management and the stability of the organisational climate. In the South African mining context, there are external factors impacting on operations of which labor, unions and worker productivity are among the foremost aspects of current concern. This served as motivation for the survey to test employee readiness for Lean Manufacturing changes to be implemented. The statistical internal consistency of the questionnaire, as expressed by the Cronbach alpha coefficients, was acceptable at 0.773 and 0.759 for the change management and organisational climate factors respectively. The p-values and effect sizes were determined within the T-test and ANOVA tests. The group consisting of different years’ experience yielded the most statistical differences in the way that the organisational climate section was completed. The indication was that highly experienced employees answered the questionnaire significantly different than the other groups. The average scoring for the section was above the average and therefore was not considered to be a significant risk to implementation. The group is considered ready for change implementation and the plant should proceed to implement the identified Lean projects. The success and sustainability of the projects can encourage additional improvements. The recommendation is to revisit the future VSM after completion of the projects to identify the next level of improvements for implementation. / MBA, North-West University, Potchefstroom Campus, 2015