Made available in DSpace on 2015-04-22T22:11:10Z (GMT). No. of bitstreams: 1 Dissertacao - Francisco Oliveira Brito.pdf: 3160975 bytes, checksum: 5f7ac8589cf0f9b2c4c2220d495e47cf (MD5) Previous issue date: 2008-07-04 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / The globalization process is demanding the food industry, especially non-alcoholic beverages, to become more competitive requiring reduction in cost and higher levels of productivity and quality. With the focus on competitiveness, an industry in Polo Industrial de Manaus - PIM has been developing management tools that integrate manufacturing and quality processes. This study examines the implementation of lean manufacturing philosophy and Six Sigma methodology in a non-alcoholic beverage company, aiming to increase the operational efficiency of its production processes. Based on bibliographical survey of the concepts, methods, procedures, quality tools, lean manufacturing, six sigma and assessment of process indicators (such as OEE Overall Equipment Efficiency) before and after implementation, is a proposed a roadmap for implementing the integration of the mentioned methodologies. The tools used in this study are: Six Sigma DMAIC (Define, Measure, Analyze, Improve and Control); Lean SMED (Single Minute Exchange Die); VSM (Value Stream Map); Kaizen; Just-in-Time and Kanban. After implementation all the steps of lean manufacturing philosophy and Six Sigma methodology, the results have showed a reduction of 73% in setup time for filler machine improving from 40 % to 64 % OEE. Finally, the poll shows that the application of Lean Philosophy with Six Sigma Methodology reduces waste and defects in the process, reflecting in productivity increase and financial profit. / Com o processo de globalização em curso, o mercado mundial para as indústrias de alimentos, em especial as de bebidas não alcoólicas se tornou ainda mais competitivo, exigindo a redução de custos e melhores níveis de produtividade e qualidade. Com o foco na competitividade uma empresa do setor de bebidas do Pólo Industrial de Manaus - PIM vem desenvolvendo ferramentas de gestão que integram a manufatura com a qualidade dos processos. Neste sentido, este estudo analisa a implementação da filosofia da Manufatura Enxuta com a metodologia Seis Sigma em uma empresa de grande porte do setor de bebidas não alcoólicas, visando o aumento da eficiência operacional de seus processos produtivos. Através de levantamento bibliográfico dos conceitos, métodos, procedimentos das ferramentas da qualidade, Manufatura Enxuta, Seis Sigma e avaliação de indicadores do processo antes e após a implementação numa empresa do setor de alimento é proposto um roteiro de aplicação da integração das mesmas. As metodologias utilizadas do Seis Sigma foram DMAIC (Definir, Medir, Analisar, Melhorar e Controlar), e da Manufatura Enxuta SMED (Single Minute Exchange Die), VSM (Mapeamento do Fluxo de Valor), Kaizen, Just-in-Time e Kanban. Após a implementação das etapas da filosofia da Manufatura Enxuta e da metodologia Seis Sigma os resultados mostram uma redução de 73% do setup da máquina enchedora de partes sólidas para empresa em estudo, passando de um OEE 40% para 64%. Finalmente, a pesquisa revela que a aplicação da filosofia enxuta aliada a metodologia Seis Sigma reduzem desperdícios e defeitos de processo, refletindo em melhorias e aumentando a produtividade e conseqüentemente o ganhos financeiros

As empresas operam em um ambiente cada vez mais dinâmico e competitivo, tornando imprescindível atender adequadamente às necessidades dos consumidores. Na atualidade, estas demandas foram ampliadas e, além de custo, qualidade, velocidade de entrega e flexibilidade, identifica-se um mercado que passa a cobrar pela redução dos impactos ambientais gerados pelos produtos e processos. Deste modo, esta pesquisa defende a proposição de que a Manufatura Enxuta, uma filosofia de gestão da produção, somada aos propósitos da Produção mais Limpa (PmaisL), uma estratégia de gestão ambiental para sistemas produtivos, pode ser uma solução para o alinhamento de seus objetivos, visto que ambas buscam o aumento de produtividade e a eliminação dos desperdícios. Para a implantação da Manufatura Enxuta não foi determinado um método que oriente como realizar este processo e quais são as práticas essenciais, além de ter poucas pesquisas que buscam compreender os fatores disto. Do mesmo modo, pesquisas que abordem a Manufatura Enxuta e a PmaisL ainda são preliminares. Neste sentido, o objetivo desta pesquisa foi propor recomendações para a implantação da Manufatura Enxuta considerando os propósitos da PmaisL, estruturadas no ciclo de melhoria contínua do método DMAIC. O método de pesquisa utilizado para alcançar o objetivo proposto foi o estudo de caso único em uma empresa de referência e o embasamento teórico foi pautado em uma revisão bibliográfica sistemática (RBS). Os resultados gerados com o desenvolvimento dessa pesquisa permitiram observar que não existe um método padrão para a implantação e que a literatura, de modo geral, aborda a implantação da Manufatura Enxuta como um processo de ciclos de melhoria continua envolvendo as atividades definir, medir, analisar, melhorar e controlar e também aborda o processo de implantação a ordem que as ferramentas e práticas devem ser implantadas. No que tange a RBS sobre PmaisL e manufatura enxuta foi possível extrair da literatura as compatibilidades e divergências entre as abordagens, recomendações para melhorar o desempenho ambiental dos sistemas enxutos, como os recursos humanos interferem na integração destas áreas e, além disso, como as práticas enxutas podem ser utilizadas para atingir os objetivos da PmaisL. Além disso, o estudo de caso permitiu observar empiricamente como o meio ambiente pode ser ponderado em um sistema de Manufatura Enxuta. Assim, com base nas evidências teóricas e práticas, gerou-se as recomendações, as quais poderão orientar as empresas de manufatura que desejam implantar as abordagens da Manufatura Enxuta e da PmaisL de maneira conjunta e obterem, simultaneamente, desempenho ambiental e econômico em suas melhorias. Ainda, foi possível concluir que apesar de existirem alguns trade-offs, estas abordagens são em grande parte convergentes. / Companies are operating in an ever more competitive and dynamic environment, making it essential to fulfil the consumers needs. Currently, these demands have expanded, and in addition to cost, quality, delivery speed and flexibility, it is possible to identify a market that requires reduction in the environmental impact of their products as well as procedures. Thus, this research supports the proposition that Lean Manufacturing, a production management philosophy, combined with Cleaner Production, the environmental management strategy for industrial systems, can be a solution for aligning goals, as both seek increased productivity and the elimination of wastage. In the implementation of Lean Manufacturing, there is as yet no method for guiding one to carry out this procedure, and to know what the essential operations are, as well as only having a few studies aimed to understand the factors involved. Similarly, the research addressing Lean Manufacturing and Cleaner Production remains at its initial stages. Thus, the objective of this research was to provide recommendations for the implementation of Lean Manufacturing considering Cleaner Production proposals, using the continuous improvement cycle structure from the DMAIC method. The research method used to achieve the proposed objective was a single case study in a notable company, and the theoretical framework was developed through a systematic literature review. The results, obtained through the development of this research, allowed us to observe that there was no standard method for deployment, and that the literature, in general, addressed the implementation of Lean Manufacturing as a process of cycles of continuous improvement, involving the defining, measuring, analyzing, improving and controlling activities; and also addressed within the implementation process the order in which the tools and operations should be implemented. With respect to RBS on Cleaner Production and Lean Manufacturing, it was possible to extract, from the literature, compatibilities and differences between the approaches; recommendations to improve the environmental performance of Lean systems, and how human resources interfered with the integration of these areas and, moreover, how the Lean operations could be used to achieve the objectives of Cleaner Production. In addition, the case study allowed the empirical observation of how the environment could be balanced in a Lean Manufacturing system. Thus, based on theoretical and practical evidence, the results generated recommendations, which could guide manufacturing companies that wanted to deploy in conjunction the approaches of Lean Manufacturing and Cleaner Production, and achieve both environmental and economical performances in their improvements. Furthermore, it was concluded that, although there are some trade-offs, these approaches are largely convergent.

As operações industriais são objeto de muitas estratégias de gestão que visam melhorar o desempenho da empresa. Dentre estas estratégias podem ser encontradas a Produção Enxuta (Lean) e a Produção mais Limpa (P+L), implementadas de forma independente segundo objetivos distintos. Contudo, na prática, é frequente observar que as estratégias interagem dentro do contexto das indústrias, potencializando o ganho de desempenho operacional/ambiental ou prejudicando uma a outra quanto a seus objetivos. A academia vem recentemente evidenciando o possível relacionamento entre Lean e P+L dando principal atenção às interações positivas entre as estratégias, havendo poucos trabalhos que observam as interações negativas ou estudam os mecanismos pelos quais é possível descrever seu relacionamento. Como resposta a esta lacuna, esta pesquisa tem por objetivo principal propor diretrizes para a integração entre o Lean e P+L nas empresas. Esta proposta de diretrizes se baseia no levantamento do estado da arte da integração entre as estratégias, que fornece as informações sobre o seu relacionamento, que são, por sua vez, verificadas empiricamente. Para executar essa estratégia de pesquisa foi feita a aplicação de dois métodos científicos: a Revisão Bibliográfica Sistemática (RBS) e o estudo de caso. A RBS, desenvolvida para analisar o conhecimento disponível sobre a integração entre Lean e P+L, investigou 5 bases de dados científicas através das quais foram avaliados 380 estudos, que após a aplicação de filtros e adição de estudos citados por estudos selecionados foi possível chegar a 38 relevantes para a avaliação da integração entre Lean e P+L. A partir desses estudos, que reúnem desde artigos em periódicos e conferências até relatórios de agências governamentais, foi possível obter informações iniciais sobre o relacionamento entre o Lean e P+L, por exemplo os principais temas de convergência e divergência e o fenômeno compartilhado entre as teorias, definidos segundo a literatura. Para verificação empírica dessas informações, foram feitos estudos de caso em duas empresas brasileiras e duas empresas inglesas para observar a integração em contextos diferentes e setores diferentes. Os estudos mostraram que, de maneira geral, os departamentos ambientais, onde a P+L é praticada, e de Lean se encontram distantes. Dessa forma, nos casos não havia iniciativa de integração entre o Lean e a P+L, mas sim interações espontâneas que levavam a benefícios os prejuízos de uma ou outra estratégia. O conhecimento, primeiramente obtido na literatura e depois submetido a uma avaliação empírica, foi reunido em diretrizes de integração dentro dos temas de integração entre o Lean e a P+L: Objetivos, Custos, Desperdícios, Ciclo de Vida, Risco Ambiental, Impactos Ambientais, Práticas, Consumidor e Sociedade, Cultura, Recursos Humanos, Requisitos Legais e Cadeia de suprimentos. Estes resultados contribuem para que, ao invés de uma abordagem segregada entre as estratégias, a sustentabilidade possa ser inserida diretamente dentro dos sistemas produtivos. Desta forma, a integração entre o Lean e a P+L passa a ser tanto uma resposta à demanda do consumidor por melhor desempenho ambiental quanto uma alternativa para que as empresas aumentem a eficiência de seus processos. / Industrial operations are the subject of many management strategies aimed at improving the company\'s performance. Among these strategies are Lean Manufacturing (Lean) and Cleaner Production (CP), implemented independently according to different goals. However, in practice, it is often observed that the strategies interact within the industries´ context, increasing the operational/environmental performance improvements or harming each others´ goals. The academy has recently started emphasizing the possible relationship between Lean and CP giving primary attention to the positive interactions between strategies, having few studies observed negative interactions or studied the mechanisms through which it is possible to describe their relationship. In response to this gap this research´s main objective is to propose guidelines for the integration between Lean and CP in companies. This guidelines proposition is based on a study of the state of the art of the integration between the two strategies which provided information about their relationship, that was in turn verified empirically. To run this search strategy two scientific methods were applied, the Systematic Literature Review (SLR) and the case study. The RBS was performed to analyze the available knowledge about the integration between Lean and CP investigated 5 scientific databases in which 380 studies were evaluated. After applying filters and adding studies cited by the selected studies, 38 studies were reached, which were the most relevant to the evaluation of the integration between Lean and CP. These studies ranged from journal and conference articles to government agencies reports, and from them it was possible to obtain the initial information about the relationship between strategies such as their main themes and the shared phenomenon defined according to the literature. For empirical verification of this information, case studies were performed in two Brazilian companies and two English companies to observe the integration in different contexts and different sectors. The studies have shown that in general the environmental departments, where CP is practiced, and Lean are distant. Thus no integration initiative between Lean and CP was observed, but spontaneous interactions that led to randomly to convergences and divergences. The knowledge obtained first literature and then subjected to an empirical evaluation was gathered in integration guidelines displayed according to the integration themes between Lean and CP: Objectives, Cost, Waste, Life Cycle, Environmental Risk, Environmental Impacts, Practices, Consumer and Society, Culture, Human Resources, Legal Requirements and Supply Chain. These results contribute to, rather than maintaining a segregated approach between strategies, inserting sustainability directly into the production systems. Consequently, the integration between Lean and CP becomes both a response to consumer demand for a better environmental performance and an alternative for companies that want increase processes efficiency.

This thesis describes line balancing of indoor optical cable production. First, the thesis explains basics of classical and lean manufacturing management and tools that helps to achieve production line improvement. This theory is the baseline for practical part. With help of analysis of movement of workers and a time study, new standard work that increases line output is set up.

A nivel mundial se sabe que, con el transcurrir de los años la industria del sector plástico se mueve en un nivel de crecimiento que está relacionado principalmente a su amplia capacidad de transformación, combinación, durabilidad y otras aplicaciones que si son correctamente empleados contribuyen a mejorar la capacidad de competitividad de las organizaciones haciendo frente a otros convertidores. Sin embargo, esta situación creciente genera que los procesos productivos se encuentren más saturado generando mayores registros de pérdidas en tiempo que impacta en el incumplimiento de la demanda, y ya que las fábricas de producción plástica venden tiempo de máquina esta situación afecta la rentabilidad de la misma. Para poder mitigar estas situaciones se han realizado diversos esfuerzos surgiendo filosofías y metodologías que permitan encontrar la solución a estos problemas, debido a la gran importancia que tiene para las empresas trabajar con la mayor eficiencia en sus procesos y con ello buscar incrementar su disponibilidad productiva para incrementar el volumen de ventas. En tal sentido, se aborda la implementación de la metodología Lean Manufacturing aplicada bajo el soporte del ciclo Deming y cuyo objetivo principal será desarrollar una estrategia en base al ciclo PHVA que permitirá incrementar la eficiencia de máquina de manera sostenida. Su aporte se desarrolla en torno a la aplicación exitosa de la combinación de las herramientas Lean seleccionadas bajo el esquema Deming y desarrolladas bajo un cronograma de Gantt para la solución del caso y que se desarrollan en este artículo pudiendo servir de guía inicial a otros técnicos que buscan incrementar la productividad de sus procesos en otras fábricas del sector. / Worldwide, it is known that, over the years, the industry of the plastic sector is moving at a level of growth that is mainly related to its broad capacity for transformation, combination, durability and other applications that, if correctly used, contribute to improving the capacity of competitiveness of organizations facing other converters. However, this growing situation means that production processes are more saturated, generating higher losses in time that impact on non-compliance with demand, and since plastic production plants sell machine time, this situation affects the profitability of the same In order to mitigate these situations, various efforts have been made to come up with philosophies and methodologies that allow finding the solution to these problems, due to the great importance for companies to work with the highest efficiency in their processes and thus seek to increase their productive availability to increase sales volume In this regard, the implementation of the Lean Manufacturing methodology applied under the support of the Deming cycle whose main objective will be to develop a strategy based on the PHVA cycle that will increase machine efficiency in a sustained manner is approached. Its contribution is developed around the successful application of the combination of the Lean tools selected under the Deming scheme and developed under a Gantt timetable for the solution of the case and that are developed in this article, being able to serve as an initial guide to other technicians who They seek to increase the productivity of their processes in other factories in the sector. / Trabajo de investigaciòn

Actualmente, las micro y pequeñas empresas (MYPEs) del sector textil no están totalmente concientizados con la importancia de llevar a cabo la aplicación de ciertos conocimientos que buscan la mejora los procesos productivos, aumento de la eficiencia y productividad, mejora la calidad y reducción de los tiempos de entrega. Para ello, se ha llevado a cabo una revisión exhaustiva de la literatura con el objetivo de recopilar modelos y técnicas del Lean Manufacturing que ayuden a reducir los desperdicios y lograr la mejora continua. En la presente investigación, se ha diseñado un modelo de Optimización de Desperdicios que incluye 3 dimensiones y cuatro componentes del sistema de producción que se relacionan con los 7 desperdicios del Lean Manufacturing. El modelo desarrollado no necesita del uso de tecnología, personal altamente calificado y puede ser implementado con gran facilidad a escenarios reales de las MYPEs textiles. Por último, se realizó un estudio de caso de aplicación del modelo de optimización en una pequeña empresa textil. Algunos resultados positivos se han registrado en la reducción del 60% de los desperdicios, tales como los defectos en las medias de algodón, movimientos innecesarios, exceso de inventarios, generando un incremento de la productividad en un 35%. Currently, the micro and small companies (MYPEs) of the textile sector are not fully aware of the importance of carrying out the application of certain knowledge that seeks to improve production processes, increase efficiency and productivity, improve quality and reduce delivery times. For this, an exhaustive review of the literature has been carried out with the objective of compiling Lean Manufacturing models and techniques that help reduce waste and achieve continuous improvement. In the present investigation, a waste optimization model has been designed that includes 3 dimensions and four components of the production system that are related to the 7 wastes of Lean Manufacturing. The model developed does not need the use of technology, highly qualified personnel and can be implemented with great ease to real scenarios of textile MYPE. Finally, a case study was carried out on the application of the optimization model in a small textile company. Some positive results have been registered in the reduction of 60% of waste, such as defects in cotton socks, unnecessary movements, excess of inventories, generating an increase in productivity by 35%. / Tesis

Analiza del proceso productivo del área de costura de una empresa textil de confección de prendas, esta área fue seleccionada para el estudio debido a que presenta deficiencias. El objetivo principal es mejorar la productividad mediante la aplicación de herramientas de Manufactura Esbelta para lograr optimizar los recursos utilizados, para esto se realizó un estudio y análisis del proceso de producción dándole mayor énfasis al área de costura de prendas para detectar, minimizar y hasta eliminar actividades que no generan valor y ocasionan sobrecostos, reducir los tiempos de entrega, las actividades de reproceso, de esta forma poder satisfacer las necesidades del cliente con un producto acorde a sus necesidades y obtener mejores beneficios para la empresa. Se obtuvo como resultado de la investigación el incremento del 9.77% de la productividad del área de costura y de la producción mensual con 204 unidades adicionales por mes por medio de la aplicación de la herramienta 5’S y la capacitación técnica para mejorar la polivalencia del personal. / Tesis

In response to the competitive global economy, lean manufacturing has become more prevalent in the United States. Manufacturing has changed, but cost accounting has not. Lean manufacturing has the potential to change the U.S. manufacturing economy, resulting in positive economic social change, yet it requires lean accounting to increase successful implementations. This study addressed the problem of lack of adoption of lean-accounting techniques like value-stream costing in lean-manufacturing enterprises. The purpose of this nonexperimental explanatory study was to investigate factors that influence the adoption of lean accounting. Using the technology acceptance model (TAM), based on the theory of reasoned action and the theory of planned behavior, this study examined whether management accountants- perceptions of the ease of use (PEOU), or perceived usefulness (PU) of value-stream costing may influence their intention (BI) to implement value-stream costing. The 2,307 attendees of the Lean Accounting Summit from 2005-2013 were invited to participate in an online survey; 70 attendees agreed to participate. Descriptive statistics, Pearson correlation coefficient, and multiple regressions were calculated. Statistically significant positive relationships emerged between PEOU, PU, and the intention to implement value-stream costing. Also, PEOU and PU for the individual accounted for 51% of the variance of BI, and PEOU and PU for the organization accounted for 49% of the variance of BI. This study added to the understanding how management accountants- perceptions positively influence their intention to implement value-stream costing. The relationships found by this study will create positive social change when used to influence the adoption of value-stream costing in order to increase the successful implementation of lean manufacturing in the U.S.

<p>In line with the company-wide CS09 project being carried out at Volvo CE Components, Cell 14 will have changes in terms of distribution of machines and parts routing to meet the lean manufacturing goals established.  These changes are of course dependant on future production volumes, as well as lot sizing and material handling considerations.</p><p>In this context, an important emphasis is given to the awareness of the performance measures that support decision making in these production development projects.  By using simulation as a confirmation tool, it is possible to re-assess these measures by testing the impact of changes in complex situations, in line with the lean manufacturing principles.</p><p>The aim of the project is to develop a discrete event simulation model following the methodology proposed by Banks et al (1999).  A model of Cell 14 will be built using the software Technomatix Plant Simulation ® which is used by the Company and the results from the simulation study will be analyzed.</p>

In line with the company-wide CS09 project being carried out at Volvo CE Components, Cell 14 will have changes in terms of distribution of machines and parts routing to meet the lean manufacturing goals established.  These changes are of course dependant on future production volumes, as well as lot sizing and material handling considerations. In this context, an important emphasis is given to the awareness of the performance measures that support decision making in these production development projects.  By using simulation as a confirmation tool, it is possible to re-assess these measures by testing the impact of changes in complex situations, in line with the lean manufacturing principles. The aim of the project is to develop a discrete event simulation model following the methodology proposed by Banks et al (1999).  A model of Cell 14 will be built using the software Technomatix Plant Simulation ® which is used by the Company and the results from the simulation study will be analyzed.