La presente investigación expone los resultados de la implementación de un Proyecto Lean Manufacturing, por medio del cual se logró la reducción de los costos generados por no conformidades del proceso de costura. Mediante el análisis realizado se identificó como principales desperdicios: los defectos, evidenciados en el alto índice de reprocesos y los recursos mal utilizados, evidenciados en el estándar de personal que realiza inspección 100% al final de los módulos de costura y el personal destinado a realizar los reprocesos. Dichos desperdicios a su vez tenían como origen la falta de estandarización de métodos de trabajo para el personal de costura, un sistema de control de calidad sesgado al “control” y no al aseguramiento de la calidad en el proceso y a la falta de un espíritu de mejora continua. Es por ello que el proyecto propuso la implementación de la estandarización, técnicas de calidad y la creación de dispositivos Poka Yoke, todas herramientas Lean, que a su vez están sostenidas por Kaizen como parte de la mejora continua. A partir de la implementación de dichas herramientas se ha logrado mejorar los indicadores de %reprocesos, pasando de 17.5% a 4.4%; eficiencia, pasando de 65% a 70%, los costos por sobretiempos del personal de calidad de S/12,013 a S/5,082 y la eliminación de las concesiones. Cada uno de estos indicadores se ha valorizado teniendo como resultado final del proyecto un TIR de 50% y un VAN de $14,479, lo que evidencia la rentabilidad de la implementación. Palabras clave: Lean Manufacturing, No conformidades, desperdicios, estandarización, mejora continua, Poka Yoke, TIR, VAN. / --- This research presents the results of the implementation of a Lean Manufacturing Project, whereby reducing the costs generated by reprocessing the stitching process is achieved. Through the analysis was identified as the main waste: defects evident in the high level of rework and resources misused and reflected in the standard of personnel performing 100% inspection at the end of modules sewing and personnel for perform the rework. Those by-turn had its origin in the lack of standardization of working methods for personal stitching, a system of quality control biased "control" rather than the quality assurance in the process and the lack of a spirit of Continuous improvement. That is why the project proposed the implementation of standardization, quality techniques, creating Poka Yoke devices, all Lean tools, which in turn are supported by Kaizen as part of continuous improvement. Since the implementation of these tools has improved indicators rework%, from 17.5% to 4.4%; efficiency from 65% to 70%, the costs for staff overtimes quality S / 12,013 S / 5,082 and removing concessions. Each of these indicators has been recovered with the final result of a TIR project 50% and VAN of $ 14.479, which shows the profitability of implementation. Keyswords: Lean Manufacturing, Nonconformities, waste, standardization, continuous improvement, Poka Yoke, TIR, VAN. / Tesis

En la actualidad, la gestión de riesgos de calidad es un tema de gran importancia en todas las organizaciones. Sus principios, que son eficazmente utilizados en diversos campos, también están siendo aplicados, de manera limitada, en la industria farmacéutica; a pesar de que la fabricación y la utilización de medicamentos implican algún tipo de riesgo. En la industria farmacéutica nacional es conocido que la tecnología utilizada para la fabricación de medicamentos está un poco desactualizado; por ende, los riesgos presentes, en sus distintas etapas de fabricación, pueden influir en directamente en los atributos críticos de calidad (CQA´s) y en la salud del paciente. Es por esta razón que nos propusimos gestionar los riesgos presentes en las etapas de secado de excipientes y envasado de polvos para suspensión oral a través de dos metodologías: Gestión de riesgos y Lean Six sigma (Lean manufacturing, metodología DMAIC) con el objetivo de identificar, mejorar, y controlar los factores que representen desperdicios o riesgos en los procesos de secado y envasado. Los resultados obtenidos en la siguiente investigación demuestran que la utilización de herramientas Lean Six-Sigma pueden ser utilizados para la reducción o eliminación de riesgos presentes en ambientes de producción farmacéutica, mejoran la eficiencia de los procesos incrementando la disponibilidad y rendimiento de los equipos; así como, aumentan la capacidad de proceso. Estas mejoras permiten reducir los riesgos asociados a estas operaciones obteniendo un proceso más seguro y eficiente. Palabras clave: Gestión de riesgo, Lean Manufacturing, Six-sigma, CQA´s, eficiencia, disponibilidad, capacidad / --- At present, the quality risk management is a major issue in all organizations. Its principles, which are effectively used in various fields are also being applied in a limited way, in the pharmaceutical industry; although the manufacturing and use of drugs involve some risk. In the domestic pharmaceutical industry it is known that the technology used for manufacturing drugs is a bit outdated; therefore, the risks involved, at various stages of production can influence directly critical quality attributes (CQA's) and patient health. It is for this reason that we set out to manage the risks in the drying stages of excipients and packaging of powder for oral suspension through two methodologies: Risk Management and Lean Six Sigma (Lean manufacturing, DMAIC methodology) with the aim of identifying, improve, and control the factors that represent waste or risks in drying and packaging. The results obtained in the following research showing that the use of Lean Six Sigma tools can be used to reduce or eliminate risks involved in pharmaceutical production environments, improve process efficiency by increasing the availability and performance of equipment; and increase the processing capacity. These improvements can reduce the risks associated with these operations to obtain a safer and more efficient process Keywords: risk management, Lean Manufacturing, Six Sigma, CQA´s, efficiency, availability, capacity / Tesis

Desarrolla el análisis y la propuesta de mejora en el proceso productivo de prendas t-shirt de la empresa en estudio, Textil Only Star S.A.C., por medio de la aplicación de herramientas de manufactura esbelta la cual permite identificar, reducir y/o eliminar todos los desperdicios (que no agrega valor al producto), y de esta manera mejorar los procesos productivos. / Tesis

Thesis PlanB (M.S.)--University of Wisconsin--Stout, 2009. / Includes bibliographical references.

'Lean Manufacturing' is a production practice that aims to reduce shop floor inventory in a manufacturing firm. Its origins extending deep into Japanese history, manufacturing works on tight material control policies and aims to achieve as close to 'stockless production' and 'zero inventories' as possible. The goals of Lean Manufacturing or the seven zeroes (zero defects, setup time, breakdowns, handling, lead time and surging) hence all strive to achieve zero inventory by producing what is needed when needed, thereby eliminating storage costs and capital tied up in inventory. The history of manufacturing in America is explored and compared to that of far eastern societies. This thesis then introduces the development of JIT, Lean Manufacturing and their immediate vii effects on the world. Techniques are explored for implementing lean methods in an automobile manufacturing firm – whether (and how) an automobile manufacturer can bring down his costs using the same and what changes will need to be done to their existing manufacturing processes. Advantages, disadvantages and possible setbacks one may encounter while attempting to implement lean methods are also explored. / text

Background: There are various manufacturing methods and systems in automobile industries throughout the world. Of these, many practice lean manufacturing methods. The most effective and influential to all of these methods is the “Toyota Production System” (TPS). The TPS was invented by Toyota's founding fathers in 1930 in Japan. The TPS continuously evolves making it a benchmark for the manufacturing, product development or any other sector of industry. It is fully based on “Socio-Technical” systems in a continuously changing manufacturing environment. It is about learn through doing and also about tacit knowledge and not explicit procedural knowledge. Outcome: The Toyota Production System is called “The Toyota Way” and it actually gives you a roadmap or more of a compass to set your direction and helps you steer your own course. Toyota has internally developed simple but effective tools and consistently trains their team members to implement those in all aspects of manufacturing and designing their vehicle. For example, Toyota has developed Kaizen or continuous improvement through which they eliminate waste that adds cost without adding value no matter how small it is. Toyota is known for the quality of their products. Not surprisingly their product is made at a significantly lower price within a given segment of the auto market. It is a result of hard work, innovation, and a Japanese work culture of generations at Toyota all across the world. Conclusions: Through theoretical analysis backed by my personal observations as an employee and from the sales figures of Toyota automobiles, I firmly believe that Toyota backs up its philosophy of long term benefits over short term financial goals. The right processes will produce right results. It is also one of the top companies among their group of long term suppliers as Toyota challenges them and helps them to improve. Initial quality and customer satisfaction surveys of J.D.Powers and Associates for Toyota and Lexus vehicles have won numerous awards since 2001. / text

Thesis (M.S.)--Rochester Institute of Technology, 2009. / Typescript. Includes bibliographical references (leaves 104-108).

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Made available in DSpace on 2014-06-11T19:32:22Z (GMT). No. of bitstreams: 0 Previous issue date: 2012-12-13Bitstream added on 2014-06-13T19:42:58Z : No. of bitstreams: 1 lourencojunior_j_dr_guara.pdf: 4002617 bytes, checksum: ca649160aa57c266beabe55dd3030837 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / É expressiva a repercussão do conceito da Produção Enxuta e grande parte das histórias de sucesso vem da indústria automotiva e de outras de fabricação de produtos discretos. Estas se caracterizam por volumes elevados e uma variedade relativamente pequena de produtos. Entretanto, constatou-se na literatura a carência de abordagens que tratem da Produção Enxuta aplicada à manufatura contínua onde os equipamentos de produção são, não raro, grandes, de elevado custo e relativamente fixos. Os processos contínuos de fabricação são menos flexíveis e não se adequam, por exemplo, a um arranjo celular como os da manufatura discreta. Neste contexto, o objetivo do presente trabalho é o de investigar a aplicabilidade do conceito da Produção Enxuta e de suas ferramentas à indústria de manufatura contínua, em particular na fabricação de condutores elétricos. Acerca da metodologia desta pesquisa, de início, um survey exploratório com fabricantes paulistas de condutores elétricos é realizado. Em seguida, a partir de dados ex-post facto de um fabricante com extenso histórico de prática dos conceitos da Produção Enxuta, foi realizado o mapeamento do fluxo de valor (VSM). Idealizou-se então o mapa do estado futuro considerado as condições de contorno e/ou adaptação das práticas enxutas a serem adotadas e seus os impactos são investigados por meio de simulação discreta estocástica. Os resultados obtidos do survey permitem inferir que o conceito ainda requer uma evolução mais significativa, naquele universo pesquisado. Já os resultados da simulação, avaliados por meio de um planejamento de experimentos e a avaliação simultânea das variáveis de saída, pelo Método Plackett-Burman, apontam a significativos ganhos, por exemplo, reduções de lead-time e estoque em processo. Em conclusão, foi... / It is significant the repercussion of the concept of Lean Production, much of the success cases come from the automotive industry and other manufacturing discrete products. Those industries are characterized by high volumes and a relatively small assortment of products. However, there was a lack of literature on approaches those address Lean Production applied to continuous manufacturing where production equipment are, not rarely, large, high cost and relatively fixed. The continuous manufacturing is less flexible and not suitable, for example, a cellular layout as discrete manufacturing. In this context, the objective of this thesis is to investigate the applicability of the concept of Lean Production and its tools for continuous manufacturing industry, particularly in the manufacture of electrical conductors. About the methodology of this research, at first, an exploratory survey with manufacturers of electrical conductors is performed. Then, data from ex-post facto from a manufacturer with long history of practice of the concepts of Lean Production was held VSM - Value Stream Mapping. After was envisioned future state map considered the boundary conditions and/or adaptation of lean practices to be adopted and their impacts are investigated by means of discrete stochastic simulation. The results of the survey allow us to infer that the concept still requires a more significant development in that universe surveyed. Already the simulation results, evaluated by means of a design of experiments and the simultaneous evaluation of the output variables, by the use of the Plackett-Burman Method, point to significant gains, for example, in reducing the lead time and the amount of stock in process. In conclusion, it was demonstrated for the industrial environment studied, continuous manufacturing eminently, the possibility... (Complete abstract click electronic access below)

Orientador: Messias Borges Silva / Banca: Fernando Augusto Silva Marins / Banca: Valério Antonio Pamplona Salomon / Banca: Robinson Damasceno Calado / Banca: Rosinei Batista Ribeiro / Resumo: É expressiva a repercussão do conceito da Produção Enxuta e grande parte das histórias de sucesso vem da indústria automotiva e de outras de fabricação de produtos discretos. Estas se caracterizam por volumes elevados e uma variedade relativamente pequena de produtos. Entretanto, constatou-se na literatura a carência de abordagens que tratem da Produção Enxuta aplicada à manufatura contínua onde os equipamentos de produção são, não raro, grandes, de elevado custo e relativamente fixos. Os processos contínuos de fabricação são menos flexíveis e não se adequam, por exemplo, a um arranjo celular como os da manufatura discreta. Neste contexto, o objetivo do presente trabalho é o de investigar a aplicabilidade do conceito da Produção Enxuta e de suas ferramentas à indústria de manufatura contínua, em particular na fabricação de condutores elétricos. Acerca da metodologia desta pesquisa, de início, um survey exploratório com fabricantes paulistas de condutores elétricos é realizado. Em seguida, a partir de dados ex-post facto de um fabricante com extenso histórico de prática dos conceitos da Produção Enxuta, foi realizado o mapeamento do fluxo de valor (VSM). Idealizou-se então o mapa do estado futuro considerado as condições de contorno e/ou adaptação das práticas enxutas a serem adotadas e seus os impactos são investigados por meio de simulação discreta estocástica. Os resultados obtidos do survey permitem inferir que o conceito ainda requer uma evolução mais significativa, naquele universo pesquisado. Já os resultados da simulação, avaliados por meio de um planejamento de experimentos e a avaliação simultânea das variáveis de saída, pelo Método Plackett-Burman, apontam a significativos ganhos, por exemplo, reduções de lead-time e estoque em processo. Em conclusão, foi... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: It is significant the repercussion of the concept of Lean Production, much of the success cases come from the automotive industry and other manufacturing discrete products. Those industries are characterized by high volumes and a relatively small assortment of products. However, there was a lack of literature on approaches those address Lean Production applied to continuous manufacturing where production equipment are, not rarely, large, high cost and relatively fixed. The continuous manufacturing is less flexible and not suitable, for example, a cellular layout as discrete manufacturing. In this context, the objective of this thesis is to investigate the applicability of the concept of Lean Production and its tools for continuous manufacturing industry, particularly in the manufacture of electrical conductors. About the methodology of this research, at first, an exploratory survey with manufacturers of electrical conductors is performed. Then, data from ex-post facto from a manufacturer with long history of practice of the concepts of Lean Production was held VSM - Value Stream Mapping. After was envisioned future state map considered the boundary conditions and/or adaptation of lean practices to be adopted and their impacts are investigated by means of discrete stochastic simulation. The results of the survey allow us to infer that the concept still requires a more significant development in that universe surveyed. Already the simulation results, evaluated by means of a design of experiments and the simultaneous evaluation of the output variables, by the use of the Plackett-Burman Method, point to significant gains, for example, in reducing the lead time and the amount of stock in process. In conclusion, it was demonstrated for the industrial environment studied, continuous manufacturing eminently, the possibility... (Complete abstract click electronic access below) / Doutor